Grey Relational Analysis of EDM Process Parameters for Incoloy-800

This project focuses on electrical discharge machining (EDM) which is a non-conventional machining process used in almost all manufacturing industries but finding the optimum process parameters is really a complex task mainly for alloys. It is known that the demand for alloy materials having unique properties is increasing but machining of these alloys using traditional method is becoming tough. So EDM is used in this project for machining alloy material and few statistical techniques were used to find out the parameters which has high impact on output. The techniques were implemented to improve Material Removal Rate (MRR) and to decrease Electrode Wear Rate (EWR) and Surface Roughness (SR). In this study, the experiments were conducted on INCOLOY- 800 using copper electrode according to L₉ orthogonal array to analyse the effect of input machining parameters viz. current (Ip), pulse on-time (T_on), pulse off-time (T_off) and flushing pressure (F_p) over the responses of MRR, EWR and SR. In this project, effect of machining process parameters viz. current, pulse-on time, pulse-off time and servo-voltage for machining Incoloy-800 using copper electrode in die sinking EDM was investigated. Experiments were performed in three levels by varying the machining process parameters. This statistical technique helps in conducting experiments economically by limiting the number of experiments. Optimization of input parameters for achieving better output responses was performed using Grey Relational Analysis and found that experiment 9’s parameters are highly influencing the output responses.