Government College Of Engineering Karad M.Tech. Production Engineering

1. GOVERNMENT COLLEGE OF ENGINEERING KARAD
(An autonomous institute of Gov. of Maharashtra)
A
Seminar on
Victrol 4003 mixed electric discharge machining
(WEDM) for optimization of Inconel alloy 800HT
using Taguchi-Grey relation analysis.
Guided by : Prof. V. S. Jadhav
Presented by : Mr. Bhushan J. Sarise
Registration No. : 18241208
DEPARTMENT OF PRODUCTION ENGINEERING
2019-20

2. CONTENTS
1. INTRODUCTION
2. LITERATURE REVIEW
3. VICTROL 4003
4. MATERIAL
5. MATERIAL COMPOSITION
6. PROPOSED WORK
7. OBJECTIVE
8. METHODOLOGY
9. EXPERIMENTAL SETUP
10.ADVANTAGES AND DISADVANTAGES
11.APPLICATIONS
12.EXPECTED WORK OUTCOMES
13.REFERENCES

3. INTRODUCTION
Wire electrical discharge machining (WEDM), also known as
wire-cut EDM is a process of using a thin single-strand of
metal wire fed through a workpiece.
Wire Electrical Discharge Machining (WEDM) is an indispensable
nontraditional machining process, capable of producing complex two
and three-dimensional shapes with good accuracy.
WEDM technology has grown tremendously since it was first
introduced to the manufacturing industry in 1969 by Agie.

4. RELEVANCE
Wire electrical discharge machining (WEDM), also known as wire-cut EDM
is a process of using a thin single-strand of metal wire fed through a
workpiece.
The wire is constantly fed from a spool is held between the upper and lower
guides. The guides move in the x-y plane and control the movement of the
wire through the workpiece during the cutting process. Most machines in
use today are CNC controlled.
Wire EDM machines are very Precise and can be programmed to cut very
intricate and delicate shapes.
The wire-cut process uses water as its dielectric with the water's resistivity
and other electrical properties carefully controlled by filters and deionizer
units.

5. LITERATURE REVIEW
Sr.
No.
Authors Nature of work Configuration
parameter
Observation/
Conclusion
1. B.V. Dharmendra Experimental INCONEL800 with
copper electrode for
high material removal
rate (MRR) and low
surface roughness
(SR).
(Ton , Toff, WF) increase
material removal rate,
maximum surface
roughness.
2. Sharanjit Singh Experimental Dielectric fluid,
powder.
Presence of metal partials
in dielectric fluid diverts
its properties, which
reduces the insulating
strength of the dielectric
fluid and increases the
spark gap between the
tool and work piece

6. 3. F.Klocke Experimental Titanium
Ti-6Al-4V
this paper aims to present
an analysis of cutting rate
related process signal
characteristics for Ti-6Al-
4V in order to
systematically increase
productivity including the
influence of different wire
electrodes.
4. Ashish Goyal Experimental Inconel 625
machining was done
by using normal zinc
coated wire and
cryogenic treated
zinc coated wire.
(Ton, Toff, WF) increase
material removal rate,
maximum surface
roughness.
5. Somvir Singh
Nain
Experimental Udimet-L605 pulse-on time,
interaction between
pulse-on time x pulse-
off time, spark-gap
voltage, surface
roughness, pulse-on
time, spark-gap voltage
and pulse-off time
,material removal rate.

7. Victrol 4003
 Victrol 4003 is the trademark for Dnr Industrial lubricants line of high
performance water miscible metal removal fluids.
 Formulated with leading edge base oils, additives, and emulsifiers, with
non-chlorinated products provides dependable performance in a wide
array of metal removal processes.
 The product is designed to work in a variety of hard and soft water qualities
and offer low foam potential and long-term corrosion protection for
machine and components.
 Low maintenance and inherently stable, Victrol 4003 is designed for the
modern machine shop where long service life, excellent machining
performance and health and environmental concerns are important factors
for increased productivity.

8. MATERIAL
Inconel alloys:
Figure 1. Inconel alloy 800 HT

9. Material Composition:
Nickel: 30%
Chromium: 20%
Iron: 40%
Carbon: 0.10 %
Aluminum: 0.60
Titanium: 0.60
Aluminum + Titanium: 1.25
1. Chemical Composition
2. Physical Constant
Density: 7.94gm/cm^3
Specific Heat: 0.11 J/kg•°C
Permeability
Annealed : 1.014
Hot-Rolled : 1.009
Curie Temperature: -115 •°C

10. PROPOSED WORK
There is need to optimize of process parameter of wire EDM process for
Victrol 4003 of material Inconel alloy 800HT using Zinc Coated/Copper Wire
and other. Therefore following work will be carried out.
 Design of experiment setup for wire EDM process for Inconel alloy 800HT
and Zinc Coated wire.
 Parametric variation of pulse on time (Ton), pulse off time (Toff), peak
current (Ip), gap voltage (Vg), wire feed rate (Wf) of wire EDM.
 Multi-Objective optimization of Victrol 4003 mixed wire electric discharge
machining is carried out by using Grey relation analysis.
 Identification of response variables such as MRR, surface roughness and kerf
width.
 Statistical analysis using S/N ratio ANOVA.
 Grey relational analysis (GRA) for Multi- Objective optimization.

11. OBJECTIVE
 To investigate the effect of WEDM process parameter on response
parameter like material removing rate(MRR), surface roughness.
 To compare MRR and SR with mixing of victrol 4003 and without
mixing of victrol 4003 in dielectric fluid.
 Optimization multiple response variable using Minitab software.
 To select the proper WEDM process parameter in order increase
surface characteristics and productivity.

12. METHODOLOGY
Flow Chart:
Material Selection (Inconel alloy 800HT)
Design Plan Taguchi Method
Measurement & Results Table Preparation
Perform Analysis Based on Grey Relational Analysis
Result Analysis and Discussion
Conclusion
End
Run Experiment According To Design Plan
Fig. (2): Flow chart of the Methodology

13. Experimental Setup
Fig.(2) Schematic representation of the WEDM system (Electronica, India)
Approximate Expenditure of work – Rs 50,000/-

14. ADVANTAGES
1. Machining time is less than the conventional process
2. The process can be applied to all electrically material and
alloys irrespective of their melting point.
3. The process can be employed for extremely hardened material
work-piece.
4. Fine hole can be easily drilled.
5. Enables high accuracy on tools and dies, because they can be
machined in as hard condition.
DISADVANTAGES
1. It cannot be applied to non-conducting materials.
2. Power required is very high compared to conventional
machining processes.
3. In some material cracking may take place.
4. Sharp corners cannot be produced.
5. Material removal rate is low.
6. Surface tend to be rough for larger removal rates.

15. Applications
1. Mold machining
2. Mechanical parts machining
3. EDM can easily machine parts with very thin walls, complex
geometry, narrow slots, small corner radii, very small features, etc. with
virtually no mechanical stress.
4. EDM can cut hardened steel, titanium, Inconel and other difficult
materials without the limitations of traditional machining.
5. EDM can achieve an excellent surface finish with no burrs right out
of the machine.
6. EDM can reduce production costs with stacked parts machining using
wire EDM as well as multi-up fixturing for wire, sinker and hole pop
EDM.
.

16. Expected Outcome of the work
The comparative study of response variable (MRR , surface roughness
, spark gap) of WEDM by variation of victrol 4003 mixed dielectric
fluid range of concentration.
The experimentation will be single objective optimization of input
parameter to get maximum MRR, minimum surface roughness and
spark gap individually.
 The contribution of each input parameter for MRR, surface roughness
and spark gap with with help of ANOVA.
 The relationship between input and response variable with help of
regression analysis and main effect plots.
 The experimentation will be multi-objective optimization process
parameter (pulse on time, pulse off time, wire feed rate, servo voltage
and victrol 4003 concentration) value of high MRR, lower surface
roughness and lower spark gap simultaneously.
The surface integrity analysis (microstructure, recast layer and EDS
analysis) for confirmation of experimental results.

17. REFERENCES
1) B.V. Dharmendra, Shyam Prasad Kodali. A simple and reliable Taguchi
approach for multi-objective optimization to identify optimal process
parameters in nano-powder-mixed electrical discharge machining of
INCONEL800 with copper electrode. The Authors Published by Elsevier
Ltd.2019.
2) Sharanjit Singh and Arvind Bhardwaj. Review to EDM by Using Water
and Powder-Mixed Dielectric Fluid. Journal of Minerals & Materials
Characterization & Engineering, Vol. 10, No.2, pp.199-230, 2011.
3) F. KlockeaL, Welschofa. Model-based Productivity Analysis of Wire EDM
for the Manufacturing of Titanium. Machine Tools and Production
Engineering (WZL) of RWTH Aachen University, Campus Boulevard 30,
520.
4) Ashish Goyal.Investigation of material removal rate and
surface roughness during wire electrical discharge machining
(WEDM) of Inconel 625 super alloy by cryogenic treated tool
electrode. Journal of King Saud University – Science 29 (2017)
528–535.

18. 5) Somvir Singh Nain, Dixit Garg,” Modeling and optimization of process
variables of wire-cut electric discharge machining of super alloy Udimet-
L605. Engineering Science and Technology, an International Journal 20
(2017) 247–264.
6) Bijaya Bijeta Nayak, Siba Sankar Mahapatra. Optimization of WEDM
process parameters using deep cryo-treated Inconel 718 as work material.
Engineering Science and Technology, an International Journal 19 (2016)
161–170.
7) Bibhuti Bhusan Biswal. Machinability analysis of Inconel 601, 625, 718
and 825 during electro-discharge machining: On evaluation of optimal
parameters setting.Department of Industrial Design, National Institute of
Technology, Rourkela 769008, Odisha, India. The Authors Published by
Elsevier Ltd.2019.
8) Fatih Uzun, Alexander M. Korsunsky. On the application of principles of
artificial intelligence for eigenstrain reconstruction of volumetric residual
stresses in non-uniform Inconel alloy 740H weldments. The Authors
Published by Elsevier Ltd.2019