Optimization of Parameters in Electrical Discharge Machining of Rene80 Nickel Base Super Alloy Using Taguchi-Grey Relational Analysis

The paper deals with the electrical discharge machining of RENE80 nickel super alloy to investigate the effects of dominant process parameters like peak current, pulse on time and pulse off time on the output responses like radial overcut, tool wear rate and metal removal rate. The experiments are planned based on Taguchi method and optimal levels of process parameters are found out using signal to noise ratio. Significant parameters are identified using analysis of variance. It revealed that the responses are mainly affected by peak current and pulse on time. In addition, multi-objective optimization of all responses is done using Taguchi-grey relational analysis and found that peak current is dominant parameter followed by pulse on time and pulse off time respectively. Finally, surface topography analysis is done using SEM, EDAX and XRD and it indicates that there is no transfer of electrode material to the work piece and alterations in phases of the alloy.