Investigation of effective parameters on surface quality of nickel based superalloy in wire cut machining using suds (Emulsion liquid in water) as dielectric

In this study, the effect of the wire cut machining parameters on the surface quality of superalloy718 was investigated. For the first time, the Inconel 718 superalloy machining was performed by wire cut method with spraying suds. This method of machining has had many advantages over the previous methods, which were immersed and cooled distilled water. The regulatory parameters were the intensity of the current, pulse lighting time, pulse power offset; forward speed and wire feed speed. Roughness and material removal rate were the Output characteristic of this process. Two methods of Taguchi design and experimental design (DOE) were used to determine the effect of the parameters on the performance of the wirecut output. Using the design of experiments in Taguchi method, the minimum roughness of the surface was 4.97 μm and the maximum roughness of the surface was 9.65 μm. The results showed that the parameters of the lighting time, the forward speed and the feeding rate of the wire increased the surface roughness and it decreased with increasing roughness time. With the analysis of the dispersion of the concentration of alloying elements on the surface, it was determined that the surface with maximum surface roughness, in addition to being sensitive to stresses and mechanical factors, has less resistance to chemical agents.