Optimization of Spark Erosion Machining of Monel 400 Alloy for Automobile Applications

Abstract

Monel 400, a type of nickel alloy which is adopted in numerous engineering fields, such as high-temperature devices. Owing to its better strength and thermal diffusion, it can be difficult to machine with conventional methods. In order to avoid the disadvantages of conventional methods, various advanced material removal techniques have been developed. One of these is Wire Electro Discharge Machining (WEDM). This process is an evolution of the electrical discharge method. In the process of WEDM, difficult materials with intricate forms are usually machined. In this study, the performance of this method on Monel 400 has been analyzed. The three independent variables that are considered when it comes to analyzing the performance of this process are the pulse on, the applied current, and the pulse off. The experiments were performed using the design approach of Taguchi, which involves using an L27 orthogonal array. The single response analysis performed by Taguchi revealed that the process parameters can influence the output variables that are desired by the users. Through the use of the Taguchi-grey relational analysis method, the multiple aspects optimization of the process was performed. The results of the exploration divulged that the proposed method can improve the effectiveness of this process.