INVESTIGATION IN UFV-μ WEDM PARAMETERS OF Ni-Cr SPACE ALLOY USING RSM TECHNIQUE

Abstract

Ultrasonic frequency vibration coupled micro-wire electrical discharge machining (UFV-[Formula: see text] WEDM) has received enormous consideration due to its zero-tolerance machining. Nickel chromium (Ni–Cr) space alloys are a natural choice within the aerospace industry, which are exposed to high temperatures and high pressure, such as turbine seals and exhaust liners. This study reveals the impact of the UFV-[Formula: see text] WEDM influencing machining parameters like ultrasonic frequency vibration (UFV), servo voltage ([Formula: see text]), time on ([Formula: see text]), cutting angle ([Formula: see text]), time off ([Formula: see text]), and current (I) on the Ni–Cr space alloy in terms of minimum surface undulation (Ra) with maximum material removal rate ([Formula: see text]). The cutting trials are carried out by central composite design (CCD). Analysis of variance (ANOVA) is used to find out the proportionate contribution of several factors, and it discloses that [Formula: see text] was the significant parameter impacting Ra (64.57%) and [Formula: see text] (61.86%). The performance sequence of significant influencing parameters is [Formula: see text]. According to desirability analysis (DA), optimum parameters for numerous solutions are [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text][Formula: see text]V, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text][Formula: see text]A, and [Formula: see text]. The optimum conditions lead to the highest [Formula: see text] (5.72[Formula: see text]mm3/min) and the lowest Ra (3.42[Formula: see text][Formula: see text]m). Scanning electron, 3D topography, and atomic force microscope images are used to analyze the machined surface.