Progressive development in the industrial field leads to the increasing demand for superalloys with enhanced mechanical properties, such as toughness, hardness, ductility, damping strength, tensile strength and improved surface finish. Monel 400, one of such superalloys, with the majority of its application in aerospace and marine fields demands a good super finish. There arises the need for some nonconventional processes like WEDM. This process is more effective to obtain complex shapes to close tolerance. This research focuses on clear understanding of the machining strategies with proper parametric combinations to achieve an improved surface finish, subsequently reducing the time and expense involved in the superfinishing procedure. The surface qualities of the selected samples are validated with the help of roughness profile and topography images. This study has proven that the increasing input current and wire feed rate (WFR) consistently decreases the surface roughness (SR; [Formula: see text] of the specimen. This paper also explains the effect of topographic parameters and microstructure over the resulting SR. In addition, the consistent contribution of WFR and input current toward the lower SR is established. The relationship between morphological behavior and parametric deviations is evaluated. A significant correlation found to exist between the rate of wire feed and the height parameters of SR such as [Formula: see text], [Formula: see text], etc.
An experimental analysis and optimization of machining rate and surface characteristics in WEDM of Monel-400 using RSM and desirability approach
