The Effect of Electrode Size on Performance Measures of Inconel X750 using Nano-SiC Powder Mixing Electrical Discharge Machining

The square hole with less than 1 mm fabricated on Inconel X750 has been challenged due to the high electrode wear and poor performance measures. Hence, the research paper deals with studying the influence of different electrode sizes on performance measures (squareness: Sq. ness, material removal rate: MRR, surface roughness: SR and electrode wear length: EWL) using nano-silicon carbide (SiC) mixing electrical discharge machining (EDM) of Inconel X750. Taguchi design has been used to design the experimental work and fabricating the square hole from 0.6 to 0.9 mm side length with 0.1 mm equal interval on Inconel X750. An influence of electrode size, pulse duration, duty cycle and current on performance measures of Inconel X750 has been studied using mean response plot. The element present in worn-out electrode surfaces has been studied using EDS analysis. Modeling and surface defects have been evaluated using a Microsoft Excel and scanning electron microscope, respectively. The additive ratio assessment (ARAS) approach is used to find the optimum process parameters. An analysis reveals the carbon layer formation due to the hydrocarbon-based dielectric through pyrolysis happening in the plasma channel. The 0.6 mm square electrode produces a square hole with less deviation compared with 0.7, 0.8 and 0.9 mm square electrodes. The 0.9 mm square electrodes have low wear length compared with other square electrodes. The performance measures are enhanced by the ARAS approach by 4% for Sq. ness, 12% for MRR, 9% for SR and 11% for EWL.