Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Parametric optimization of wire electro discharge machining of Inconel

718 using Taguchi’s methodology
Alok Kumar, Shankar Singh
Department of Mechanical Engineering, Sant Longowal Institute of Engineering & Technology, Longowal, 148106 Sangrur, Punjab, India

a r t i c l e i n f o a b s t r a c t

Article history: In this demanding world of advanced technologies, the Wire Electro Discharge Machining (WEDM) has
Received 20 August 2020 evolved as one of the promising methods for efficient machining of advanced materials (super alloys,
Received in revised form 5 November 2020 ceramics and composites). WEDM, an important advanced machining process meets the demands of pre-
Accepted 20 November 2020
cise complex geometry and effective stock removal.
Available online xxxx
The work material chosen for the present study is Nickel based age-hardenable austenitic super alloy
Inconel 718, having high strength, better oxidation-corrosion resistance, and high temperature resis-
Keywords:
tance. Inconel 718 finds widespread application in aerospace, marine, automobile industries, nuclear
WEDM
Taguchi’s analysis
power, and oilfield applications.
Parametric optimization The present study deals with the experimental analysis and parametric optimization of slitting Inconel
ANOVA 718 with brass wire using WEDM. The objective of the proposed work is to optimize the process param-
Performance measures eters namely Pulse-on time (TON), Open Circuit Voltage (OV), Wire Tension (WT) and Wire Feed Rate
(WFR). The required experiments were conducted using Taguchi’s Orthogonal Array [L9 (34)] to predict
optimal parametric settings for the responses namely Surface Roughness (SR) and Material Removal
Rate (MRR).
The results of ANOVA show that TON has highest influence on MRR followed by OV, WFR and WT. TON
has highest influence on SR followed by WFR, WT and OV. When OV or TON increases then MRR also
increases. When TON or OV or WFR decreases then SR also decreases. The optimal parameter for MRR
is OV-60 V, TON-0.75 ms, WFR-1 m/min, WT-1700 g and for SR is OV-50 V, TON-0.25 ms, WFR-1 m/min
and WT-1100 g.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Advanced Materials Behavior and Characterization.

1. Introduction has high hardness, toughness, work hardening tendency, chemical

In present manufacturing scenario, to fulfill the requirement of
advanced technologies in aerospace, aircraft, nuclear, marine, and
chemical industries, demand of Inconel 718 increases rapidly.
Inconel 718, a Nickel based age-hardenable austenitic super alloy
which may be used in extreme environment subjected to heat
(up to 705 °C) and pressure as well as very low temperature (upto

253 °C). It has high oxidation- corrosion- temperature resistance,
high strength (tensile, fatigue, creep, and rapture), durability,
toughness, stiffness, and dimensional stability. It is widely used
for making various crucial components of gas turbine, high pres-
sure part of compressor, liquid fuelled rocket, aircraft, spacecraft,
nuclear reactors, and oilfield applications [1,2]. However, machin-
ing of Inconel 718 by traditional method is very difficult because it
affection to tool material and high thermal resistance. [1,3]
In this demanding world by advanced technologies, the WEDM
has evolved as one of the promising method for efficient machining
of advanced materials namely super alloys, ceramics and compos-
ites. It can produce component with precise complex geometry and
features, high quality surface finish, burr free surface thus, elimi-
nate the need of post finishing operation [4,5]. Effective optimiza-
tion of WEDM parameters affects dramatically the cost, production
rate and quality of the products [6].
Caydas and Ay [3] machined Inconel 718 on WEDM using brass
wire and experimentally studied the effect of machining character-
istics on the cutting quality namely SR, Kerf Width and Recast Layer
Thickness. The author found that when Peak Current (IP) or Pulse-on
time (TON) increases then SR also increases. Effect of Flushing Pres-

https://doi.org/10.1016/j.matpr.2020.11.730
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advanced Materials Behavior and Characterization.

Please cite this article as: A. Kumar and S. Singh, Parametric optimization of wire electro discharge machining of Inconel 718 using Taguchi’s methodology,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.11.730
A. Kumar and S. Singh
sure (FP) is very less on cutting quality. Chaubey et. al. [5] has stud-
ied the effects of TON, WT, WFR and IP on SR and MRR while machin-
ing AISI D2 Tool Steel using brass wire. It was observed that when
WT increases then MRR slightly decreases non-linearly and SR first
increases upto certain limit after that it decreases. When WFR
increases then MRR and SR decreases. When TON increases then SR
and MRR increases. Liu et al. [7] looked into the effect of Open Cir-
cuit Voltage (OV) in micro EDM while machining Ni-Al2O3 using
graphite electrode of diameter 1 mm and kerosene dielectric fluid.
It was concluded that when OV increases then Material Removal
Rate (MRR) and SR also increases because energy per discharge
increases. Dabade and Karidkar [8] studied the WEDM Performance
Characteristics while machining Inconel 718 using brass wire and
de-ionised water. It was observed that when Wire Tension (WT),
Pulse-off time (TOFF) decreases or TON increases then SR increases.
When TON or WT increases then MRR increases. When TOFF or Wire
Feed Rate (WFR) decreases, then MRR increases. Tonday and Tigga
[9] empirically evaluated and optimize the SR and machining time
while machining Inconel 718. It was identified that TON has maxi-
mum influence on SR and machining time. Lower SR can be achieved
with lower value of TON. Aggarwal et. al. [10] has done parametric
modeling of WEDM parameters using Response Surface Methodol-
ogy (RSM). Inconel 718 was cut using Zinc coated brass wire and
de-ionised water. It was noticed that when TON, IP increases or TOFF
decreases then Cutting Rate increases. SR is minimum when combi-
nation of TON and IP is lower. Ramakrishnan and Karunamoorthy
[11] optimized WEDM process parameters with multiple responses
(MRR and SR) while machining Inconel 718 using brass wire. The
author was observed that when TON increases then MRR increases
but quality of machined surface deteriorates. SR decreases with
increase in WFR. Verma et. al. [12] has performed WEDM on En-
31 tool steel and observed that TON has strongest effect on MRR,
Taper Error and SR followed by Taper Angle, WT and WFR.
It is evident from the literature review that a lot of research has
been reported on effect of TON, TOFF, WFR, WT, Peak Current extra in
WEDM, but very few research have been reported on effect of OV in
WEDM. No literature seems to be available on Parametric Opti-
mization of WEDM process parameters (combination of OV, TON,
WFR and WT) for Inconel 718 at the level taken in this study.
The present work bridges this gap. The main purpose of the pro-
posed work is to understand the effect of process parameters like
OV, TON, WFR and WT on the slitting process of Inconel 718 using
WEDM, so the Parametric conditions delivering maximum MRR
and minimum SR can be achieved.
2. Experimentation
2.1. Work material
Inconel 718 plate of dimension 120 mm  100 mm  6 mm has
chosen as work material for the proposed study. Inconel 718 (ASTM
B637), a nickel based super alloy having yield strength 1100 MPa,
density 8.19 g/cm3, ultimate tensile strength 1375 MPa, Hardness
Rc 36, thermal conductivity 11.4 W/m.K and melting range
1260 °C to 1336 °C. It has high resistance to oxidation, creep, corro-
sion, and fatigue [1,2]. Work specimen before machining is shown
in Fig. 1. Chemical composition of work material (Inconel 718) as
per Positive Material Identification Report given by Advanced PMI
Solutions, Girgaon (Mumbai) (provided through the supplier Bha-
gyashali Metal, Mumbai 400004) is given in Table 1.
2.2. Methodology
In the present study four factors have been chosen with 3 levels
each. The Taguchi’s L9(34) Orthogonal array was used to perform
2
Materials Today: Proceedings xxx (xxxx) xxx
Fig. 1. Work specimen before machining.
experimental runs, where, no. of levels = 3, no. of factors = 4, no.
of experiments = 9= (3–1)  4 + 1. In L9 orthogonal array, no. of
rows is 9, maximum no. of factors is 4 and maximum number of
columns at these levels are 4 [13,14].
Four parameters namely Open Circuit Voltage (OV-V), Pulse on
time (TON- ms), Wire Feed Rate (WFR- m/min), Wire Tension (WT-
g) were selected. The levels of each process parameter have been
selected based on the capability of WEDM machine and prelimi-
nary experiments conducted. The preliminary experiments were
carried out with OFAT (one factor at a time) to observe the notice-
able effects on machining characteristics.
Levels of parameters were fixed based on preliminary experi-
ments conducted and the capability of WEDM machine for effec-
tive machining. They were suitably assigned to avoid serious
problems like wire breakage, short circuiting of wire electrode,
damage of work surfaces, to have better results for higher
productivity.
The fixed parameters of WEDM during experimentation are:
Pulse off time- 12 ms, Servo voltage- 40 V, Arc on time- 0.2 ms, Arc
off time- 18 ms, De-ionized water flow- 4 Kgf/cm2, Wire
diameter- 0.25 mm, Workpiece thickness
6 mm.
Results were analyzed using Regression Analysis and optimiza-
tion is done using Taguchi’s Analysis. Each experimental runs as
per selected Orthogonal Array (OA) were replicate twice to reduce
the error (experimental) and the arithmetic average values of MRR
and SR were considered for analysis Thus, total number of experi-
ments performed were 9  2 = 18. The selected four process
parameters as discussed earlier are OV, TON, WFR and WT, all hav-
ing three levels each. Table 2 shows the input parameters and their
respective levels, considered in the proposed study.
2.3. Experimental procedure
The required experiments were executed on an EXCETEK EX 40
WEDM machine (Excetek Technologies Co. Ltd, Taiwan). A single
stranded plane brass wire (Cu60Zn40) of diameter 0.25 mm (hav-
ing tensile strength 550–750 MPa) was used as wire electrode
and de-ionised water (having conductivity of 20mho) was used
as dielectric fluid. A program was made and cuboidal specimens
of length 15 mm, width 15 mm and thickness 6 mm were cut.
Work specimen before machining is shown in Fig. 1and mounted
and clamped workpiece on work table is shown in Fig. 2.
2.4. Measurement of performance characteristics
Following equation has been used for calculation of MRR in the
proposed study:
W
W

MRR ¼ qi t f mm3 =min
A. Kumar and S. Singh
Table 1
Chemical composition of Inconel 718.
Elements Cr Ni
Weight (%) 17.61 54.69
Table 2
Considered process parameters and their respective levels.
Sl. No. Name Factor
1 Open Circuit Voltage A OV
2 Pulse On Time B TON
3 Wire Feed Rate C WFR
4 Wire Tension D WT
Fig. 2. Mounted and clamped workpiece on worktable.
where, Wi and Wf are the weight of work specimen before
machining and after machining respectively (in g), tm is the
machining time (in min) and q is the work material density (in
g/mm3) [5,12]. Electronic balance (Make: Citizon, Model:
CY1003) was used for measuring Weight of the work specimens.
Machining time was measured using stopwatch which have least
count of 0.01 s. Surtronic 25 (Taylor Hobson), a Surface Roughness
tester was used for measuring SR of the machined work specimen.
An evaluation length 4.0 mm and cut-off length 0.8 mm were taken
for the measurement. The Surface Roughness for each work speci-
men was measured four times (each side was measured single
time) and their average was considered so that experimental error
would be minimum.
3. Experimental results, analysis, and discussions
3.1. Experimental results
Table 3 shows the results obtained from slitting (cutting) of
Inconel 718 using (WEDM). The experiments were performed
based on L9 orthogonal array.
3.2. Analysis of MRR (mm3/min)
Multiple regressions for MRR are shown in the Table 4. P-value
determines whether the hypothesis test results are significant or
not. If the p-value is less than the significant value (95% in the pre-
sent study i.e. 0.05), it means that null hypothesis is rejected, and
the process parameters has significant effect on the response
variables.
Materials Today: Proceedings xxx (xxxx) xxx
Nb Mo Ti
5.26 2.83 0.90
Symbol Unit Levels
1 2 3
V 50 55 60
ms 0.25 0.50 0.75
m/min 1 2 3
g 1100 1400 1700
Since ‘P’ value for OV and TON are less than 0.05 so, OV and TON
have statistically significant effect on MRR (at the 95% confidence
level).
The equation of the fitted Multiple Linear Regression Model is:
S=N MRR ¼ 15:003 þ 0:0374 OVðVÞ þ 2:466 TON ðlsÞ

0:0514 WFRðm=minÞ þ 0:000240 wtðgÞ
F-test determines whether the regression model provides better
fit to the data than a model that contains no independent variable.
It compares the p-value for the F-test to significance level (95% in
the present study i.e. 0.05). From Table 5 and 8, it can be inter-
preted that as p-value for regression model is less than 0.05, which
signifies that null hypothesis is rejected or in other words alterna-
tive hypothesis is accepted. Hence, regression model provides bet-
ter fit to the data.
Since, the ‘p’ value for WFR and WT are greater than 0.05, so
WFR and WT are not statistically significant (at 95% or higher con-
fidence level). So WFR and WT may be omitted from the regression
equation. Thus, the final model (after omission of WFR and WT)
can be expressed as follows:
S=N MRR ¼ 15:003 þ 0:0374 OVðVÞ þ 2:466 TON ðlsÞ
In the ANOVA Table (Table 5) p < 0.05 which indicates that
there is a statistically significant relationship between the vari-
ables (at the 95% confidence level). Larger the better S/N ratio is
chosen for MRR because it is desirable.
From the response Table (Table 6) the delta value for TON is
highest among delta values for other process parameters so, it is
ranked first. It indicates that TON has highest influence on the
MRR. Thus, the influence of process parameter on MRR in descend-
ing order can be seen as TON, OV, WFR and WT.
3.3. Main effects plot for S/N ratios of MRR
The main effect plots for MRR are shown in Fig. 3. The main
effects plots give the optimal combination of testing parameters
for the desired responses. It also gives a rough idea about the rel-
ative significance of the process parameters on the responses.
These effects plot shows that OV affects the MRR significantly.
When OV increases then MRR initially increases rapidly after that
MRR increases slowly. As the OV increases, the energy per spark
increases which increases the amount of erosion thus, MRR
increases rapidly. As the OV continues to increase, it is difficult
to remove the eroded particles due to which MRR increase slowly.
This is in consonance with earlier observations for WEDM [7]. It
can be seen from Fig. 3 that the TON parameter is seeing a steep
rise, shows that TON affects the MRR significantly (If the slope is
steep showing rise, the parameter is significant). MRR increases
3
A. Kumar and S. Singh Materials Today: Proceedings xxx (xxxx) xxx

Table 3
Experimental Results with S/N ratio.

Run Process Parameters Performance Measures S/N Ratio

OV(V) TON(ms) WFR(m/min) WT(g) Material Removal RateMRR Surface RoughnessSR (mm) MeanMRR MeanSR
(mm3/min)
1 2 Mean 1 2 Mean
1 50 0.25 1 1100 7.6630 7.7036 7.6833 2.163 2.167 2.165 17.7110
6.7092
2 50 0.50 2 1400 8.6395 8.6575 8.6485 2.925 2.955 2.940 18.2625
9.3669
3 50 0.75 3 1700 8.9110 8.8758 8.8934 3.780 3.770 3.775 18.9814
11.5383
4 55 0.25 2 1700 7.5157 7.5637 7.5397 2.362 2.378 2.370 17.9112
7.4950
5 55 0.50 3 1100 8.5640 8.4858 8.5249 3.120 3.110 3.115 18.6138
9.8692
6 55 0.75 1 1400 9.1722 9.1368 9.1545 3.544 3.516 3.530 19.2327
10.9555
7 60 0.25 3 1400 7.7410 7.7376 7.7393 2.504 2.526 2.515 18.0073
8.0108
8 60 0.50 1 1700 8.5906 8.6230 8.6068 3.076 3.044 3.060 18.9094
9.7144
9 60 0.75 2 1100 8.9900 9.0290 9.0095 3.428 3.452 3.440 19.0940
10.7312

Table 4
Regression Analysis for MRR (mm3/min).

Term Coef SE Coef T-Value P-Value VIF

Constant 15.003 0.824 18.20 0.000
OV (V) 0.0374 0.0134 2.79 0.049 1.00
TON (ms) 2.466 0.268 9.20 0.001 1.00
WFR (m/min)
0.0514 0.0670
0.77 0.486 1.00
WT (g) 0.000240 0.000223 1.07 0.344 1.00

Table 5
ANOVA for MRR.

Source DF Adj SS Adj MS F-Value P-Value

Regression 4 2.53686 0.63421 23.55 0.005
Error 4 0.10770 0.02693
Total 8 2.64456

Table 6
Response Table for MRR.

Level OV (V) TON (ms) WFR (m/min) WT (g)

1 18.31 17.87 18.63 18.47
2 18.58 18.61 18.41 18.49
3 18.69 19.10 18.53 18.62
Delta 0.37 1.23 0.22 0.14
Rank 2 1 3 4

Fig. 3. Main Effects Plot for S/N ratios of MRR.

4
A. Kumar and S. Singh Materials Today: Proceedings xxx (xxxx) xxx

approximately linearly with increase in TON. Energy per discharge
increases with increase in TON hence, more time is provided for
each spark which leads to increase in MRR. This is in consonance
with earlier observations for WEDM [5,15]. When WFR increases
then MRR first decreases linearly after that it increases linearly.
This is in consonance with earlier observations for WEDM [16].
When WT increases then MRR first increases slowly after that it
increases at relatively faster rate. Increment is approximately
linear. This is in consonance with earlier observations for
WEDM [16].
In Taguchi’s method, signal represents response variable value
whereas, noise represents uncontrollable parameters that cause
variability in the product. Taguchi’s S/N ratio makes the design
robust, means the design is least sensitive to noise. Higher values
of the signal-to-noise ratio (S/N) identify process parameters set-
tings that minimize the effects of the noise factors. The optimal
parametric settings for each parameter are the level having highest
value of S/N ratio. From the above analysis the optimal parameters
for MRR are A3B3C1D3 (i.e. OV-60 V, TON-0.75 ms, WFR-1 m/min
and WT-1700 g).
3.4. Analysis of SR (mm)
Multiple Regressions for SR are shown in the Table 7. Since ‘P’
value for TON and WFR are less than 0.05 so, TON and WFR affects
the SR significantly (at the 95.0% confidence level).
Regression equation of the fitted model is:
SRðlmÞ ¼
2:49

0:0243 OVðVÞ
7:101 TON ðlsÞ

0:359 WFRðm=minÞ
0:000935 wtðgÞ
Since the ‘P’ value of OV and WT are greater than 0.05, therefore
OV and WT is not statistically significant at 95.0% Confidence Level.
Consequently, we may omit OV and WT from the model. Thus the
final model (after omission of OV and WT) can be express as
follows:
SRðlmÞ ¼
2:49

7:101 TON ðlsÞ
0:359 WFRðm=minÞ
In the ANOVA table (Table 8) p < 0.05 which indicates that there
is a statistically significant relationship between the variables (at
the 95.0% confidence level). Smaller-the-better S/N ratio is chosen
for SR because it is desirable. From the response Table (Table 9) the
delta value for TON is highest among delta values for process
parameters so, it is ranked first. It indicates that TON has highest
influence on the SR. Thus, the influence of process parameter on
SR in descending order can be observed as TON, WFR, WT and OV.
3.5. Main effects plot for S/N ratios of SR
Fig. 4 shows the main effect plots for SR. These plots show the
variation of SR with the OV, TON, WFR and WT separately. It shows
that when OV increases then SR increases slightly. As OV increases
energy per discharge also increases, which produces larger dis-
charge crater (strong spark). Hence SR of the machined surface
increases. This is in consonance with earlier observations for
WEDM [7]. It can be seen from Fig. 4 that the TON parameter is see-
ing a steep rise (In the graph, values of S/N ratios of SR are in -ve),
shows that TON affects the SR significantly. SR increases approxi-
mate linearly with the increase in TON because energy per spark
increases with increase in TON which generates violent spark. It
produces deeper and irregular sized craters which increases the SR.
It also provides higher time for each spark leading to more
melting and re-solidification of work surface results increase in
SR. This is in consonance with earlier observations for WEDM
[5,17]. SR slightly increases with increase in WFR. SR slightly
increases with increases in WT. This is in accordance with what
has been observed for WEDM [6]. The optimal parameter for SR
is A1B1C1D1 (i.e. OV-50 V, TON
0.25 ms, WFR-1 m/min, WT-
1100 g). It can be seen from Fig. 3 and Fig. 4, the other factors do
have some effects, but the most influential is TON. The results are
based on the experimental data.

Table 7
Regression Analysis for SR.

Term Coef SE Coef T-Value P-Value VIF

Constant
2.49 1.48
1.69 0.166
OV (V)
0.0243 0.0240
1.01 0.369 1.00
TON (ms)
7.101 0.480
14.80 0.000 1.00
WFR (m/min)
0.359 0.120
2.99 0.040 1.00
WT (g)
0.000935 0.000400
2.34 0.079 1.00

Table 8
ANOVA table for SR.

Source DF Adj SS Adj MS F-Value P-Value

Regression 4 20.2410 5.0603 58.65 0.001
Error (residual) 4 0.3451 0.0863
Total 8 20.5861

Table 9
Response Table for S/N ratios of SR.

Level OV (V) TON (ms) WFR (m/min) WT (g)

1
9.205
7.525
9.088
9.088
2
9.560
9.612
9.317
9.317
3
9.447
11.075
9.806
9.806
Delta 0.355 3.550 0.718 0.718
Rank 4 1 2 3

5
A. Kumar and S. Singh
Fig. 4. Main Effects Plot for S/N ratios of SR.
4. Conclusions
In this experimental work, the effects of OV, TON, WFR, WT on
MRR and SR was investigated while slitting (cutting) Inconel 718.
Taguchi’s Optimization Technique is used to obtain optimal param-
eter combination for minimization of SR and maximization of MRR.
Some important conclusions are drawn from the study after ana-
lyzing the results of the experiments:
1. The results of ANOVA for MRR showed that TON has highest
influence on MRR followed by OV and WFR. WT has the little
influence on MRR.
2. MRR increases with increase in OV because energy per dis-
charge increases. MRR increases approximately linearly with
increase in TON because energy per discharge increases. MRR
first decreases linearly after that it increases linearly with
increases in WFR. MRR increases approximately linearly with
increase in WT.
3. The results of ANOVA for SR showed that TON has highest influ-
ence on SR followed by WFR and WT. OV has little influence on
SR.
4. SR increases slightly with increase in OV. Larger craters (strong
sparks) are produces at higher OV leads to increase in SR. When
TON increases then SR increases approximately linearly. Longer
TON generates violent spark which produces deeper and irregu-
lar sized crater thus, SR increases. When WFR increases then SR
increases slightly. When WT increases then SR increases
slightly.
5. The optimal parameters for MRR are A3B3C1D3 (i.e. OV- 60 V,
TON- 0.75 ms, WFR-1 m/min, WT-1700 g).
6. The optimal parameters for SR are A1B1C1D1 (i.e. OV- 50 V,
TON- 0.25 ms, WFR-1 m/min and WT-1100 g).
7. Further it has been also seen that Regression Analysis is suitable
for WEDM process of Inconel 718, for suggesting mathematical
model.
CRediT authorship contribution statement
Alok Kumar: Conceptualization, Methodology, Formal analysis,
Investigation, Visualization, Writing - original draft. Shankar
Singh: Software, Validation, Resources, Supervision, Project
administration.
6
Materials Today: Proceedings xxx (xxxx) xxx
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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