Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564 Received for review: 2019-06-13

© 2019 Journal of Mechanical Engineering. All rights reserved. Received revised form: 2019-08-26
DOI:10.5545/sv-jme.2019.6194 Original Scientific Paper Accepted for publication: 2019-09-10

Analysis of EDM Process Parameters on Inconel 718

Using the Grey-Taguchi and Topsis Methods
Thangavel, Y. – Paramasivam, S.
Thangavel Yuvaraj* – Paramasivam Suresh
Muthayammal Engineering College (Autonomous) Rasipuram, Department of Mechanical Engineering, India

Nickel-based superalloys are gaining importance for their growing usage in aerospace industries. Amidst the various advanced machining
processes, electro discharge machining (EDM) is considered to be an important one for its ability to machine materials irrespective of its
intrinsic properties. In this study, Inconel 718 is considered as a work material, and an L18 orthogonal array (OA) experimental plan is utilized
to machine the work material. The influential factors, which affect the EDM performance characteristics, are identified using analysis of
variance (ANOVA). Not much work has been done regarding using grey-Taguchi technique for order of preference by similarity to ideal solution
(TOPSIS) methods, although these methods can be easily applied for multi-objective optimization. These methods provide the best results with
the available sparse data. The best combination of machining factors is determined using grey-Taguchi and TOPSIS methods. Based on the
conducted experiments, voltage (V) and pulse off-time (toff) show a notable contribution on output performance. The optimal combination of
input parameter through grey-Taguchi is found to be 10 A, 30 V, 200 µs, and 20 µs respectively, for the EDM parameters: current (I), V, pulse
on-time (ton) and toff for improved response. Moreover, the best parameter setting (I = 10 A, V = 30 V, ton =100 µs and toff = 20 µs) is identified
using the TOPSIS method for the performance measures machining rate (MR), tool wear rate (TWR), overcut (OC), and taper overcut (TOC).
Further tool wear behaviour is also studied through scanning electron microscope (SEM) images by varying the voltage.
Keywords: Inconel, ANOVA, grey-Taguchi, overcut, taper

Highlights
• EDM process parameters(voltage, current, pulse on- time and pulse off- time) were optimized through the L18 orthogonal
experimental design method, and the grey relational analysis (GRA) method, considering multi-responses, such as machining
rate (MR), tool wear rate (TWR), overcut (OC), and taper overcut (TOC).
• The methods grey-Taguchi and TOPSIS were used to study the influential parameters that provide the best results with the
available sparse data.
• Based on GRA and TOPSIS, the optimum level parameters for EDM have been identified. Furthermore, the tool wear behaviour
is also studied through SEM images by varying the voltage.
• The optimal combination of the input parameter to acquire better responses based on grey-Taguchi has been found to be (10
A), V (30 V), ton (200 µs), and toff (20 µs). According to ANOVA, the voltage and toff plays a prominent role in machining Inconel
718.
• The best combinations identified using the TOPSIS method for better performance measures is 10 A, 30 V, 100 µs and 20 µs.

0 INTRODUCTION different powders, such as graphite, silicon, and

aluminium [3] and [4]. Torres et al. [5] investigated
Electro discharge machining (EDM) has a one-off the behaviour of an Inconel 600 alloy through EDM
significant process for the machining of hard materials process. They studied the electrical parameters’
and superalloys. Heat-resistant superalloys (HRSA), influence and concluded that the change in polarity
especially the Inconel alloy, find applications in has a significant influence on surface quality.Tanjilul
aerospace and marine components, cryogenic storage et al.[6] reported that a novel flushing method and a
tanks, and nuclear reactor components. Understanding machining current significantly influences the debris
the importance of the Inconel alloy, manufacturing removal. The size of the debris particles increases
scientists and engineers are attempting to understand with increasing machining current. Rajesha et al.
the behaviour of it through EDM processes. In the [7] studied the effect of process parameters such as
machining of Inconel 718, Shen et al. [1] applied current, duty cycle, sensitivity control, inter-electrode
high-speed EDM with air as a dielectric medium and gap control, and flushing pressure on the material
produced components with better surface quality. removal rate (MRR) and surface roughness (SR).
The importance of powder-mixed dielectric fluid in They found that the pulse current and duty factor
the EDM for machining Inconel alloy was analysed has the highest influence. Kuppan et al. [8] reported
by Talla et al. [2]. The researchers revealed better that the MRR and SR increase with the increase
results for surface quality and accuracy while using in peak current, duty factor, and electrode speed.
*Corr. Author’s Address: Department of Mechanical Engineering, Muthayammal Engineering College (Autonomous), Rasipuram, India,[email protected] 557
 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

Mohanty et al. [9] conducted an L9 orthogonal array through scanning electron microscope (SEM) images
(OA) and optimized the EDM process parameters of by varying the voltage.
Inconel 825 using grey relational analysis (GRA).
The parameters combination ( I (1A), ton (10 µs), and 1 EXPERIMENTAL
duty cycle (75 %)) showed good results for the rate of
material removed, surface quality, and radial overcut. The experimental set-up for EDM machining
Mohanty et al. [10] highlighted the importance process is shown in Fig. 1. It consists of a maximum
of cryogenic treatment of tool in EDM on output working voltage of 415 V, maximum current of 25 A,
performance using technique for order of preference work table size of 600 mm × 400 mm, a maximum
by the similarity to ideal solution (TOPSIS) method electrode length of 400 mm, and a servomotor for
and teaching–learning-based optimization algorithm. inter-electrode gap control. Inconel 718 has been
Dang [11] optimized the EDM parameters using selected as a workpiece material, whereas a brass
a kriging model and particle swarm optimization electrode of Ø 0.5 mm is used with EDM oil as the
method,finding that the model and method is suitable dielectric medium. Tables 1 and 2 provides the details
for the optimization of EDM process. Lin et al. [12] of chemical and mechanical properties of Inconel
optimized and enhanced the EDM process parameters 718 [16]. The thickness of workpiece is 3.1 mm.
for Inconel 718 through multi-objective optimization Since the discharge energy is primarily determined
technique using grey-Taguchi. Muthuramalingam by current (I), voltage (V), pulse on-time (ton), and
and Mohan [13] machined SS 201 through EDM pulse off-time (toff), these factors are used as the input
and established the importance of peak current. parameters. These parameters are selected based on
Lin et al. [14] conducted experiments on Ti-6Al-4V the literature review, and levels are identified based
alloy through Micro-EDM and studied the influence the preliminary experiments;10 A, 12 A and 14 A have
of process parameters and gaps using the grey been considered as current variables; 30 V, 40 V and
relational analysis (GRA)-Taguchi technique. The 50 V have been chosen as voltage variables;100 µs,
use of the GRA with Taguchi technique yields better 150 µs and 200 µs have been chosen as ton values with
results for tool electrode wear and overcut.Based toff values of 20 µs, 30 µs and 40 µs. Table 3 shows the
on the above literature, the characteristics of EDM experimental layout using an L18 OA. MR is calculated
for machining holes on Inconel 718 are influenced by dividing the length of the through hole with the
by various input parameters. Each performance machining time required to complete the through hole.
characteristic has different combinations of optimal TWR is calculated using the relation mass is ρ × v,
process parameters and thus, in the case of multiple where ρ is brass density, v volume of brass tool (πr2h),
responses, the selections of optimal machining h brass tool height. During the start and end of each
parameters are difficult. The grey system, proposed
by Deng [15], handles the vague information and
thus the GRA method is recommended as a principal
method for multiple response optimisation. Therefore,
researchers optimized the machining of Inconel 718
using electrical parameters and inter-electrode gap
(IEG).In this paper, EDM process parameters: I, V,
ton and toff were optimized through the L18 orthogonal
experimental design method, and the GRA method
considering multi-responses, such as machining rate
(MR), tool wear rate (TWR), overcut (OC) and taper
overcut (TOC). Not much work has been done using
the grey-Taguchi and TOPSIS methods although these
can be easily applied for multi-objective optimization.
The significant contribution of this research is in using
these methods to study the influential parameters
that provide the best results with the available sparse
data.Based on GRA and TOPSIS, the optimum
level parameters for EDM have been identified.
Furthermore, the tool wear behaviour is also studied Fig. 1. Experimental setup

558 Thangavel, Y. – Paramasivam, S.

 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

Table 1. Chemical composition of Inconel 718 (weight %)

C Mn Si Cr Ni Co Mo Nb+Ta Ti Al Fe
0.040 0.08 0.08 18.37 53.37 0.23 3.04 5.34 0.98 0.50 17.80

experiment, the length of the brass tool is measured, is considered and the obtained MR data values are
and the difference is noted as h; this value is used to homogenized as shown below [14]:
calculate the volume of brass electrode. The ratio of x j ( i ) − min x j ( i )
volume of electrode wear to the time taken to complete x*j ( i ) = , (1)
min x j ( i ) − min x j ( i )
the experiment is called TWR. OC is calculated
using optical microscopic images. OC is defined by where x*j ( i ) are the homogenized MR after the
ΔR = Re – Rt, where Re is the entrance radius of the preprocessing, is the signal-to-noise ratio of the MR,
machined hole and Rt the tool electrode radius.The where i = 1 for MR; i = 1, 2, 3, …, 18 for experiments 1
difference in Re and Rt results in OC. TOC is defined to 18.
by TOC = D – d / (2L), where, D is entry diameter of EDM performance is also measured using TWR,
the machined hole, d exit diameter of the machined OC and TOC. Hence, to achieve better machining
hole, and L thickness of the workpiece. quality, the “smaller-the-better” is considered in view
of minimizing TWR, OC, and TOC. Therefore the
Table 2. Mechanical properties of Inconel 718 actual sequence must be normalized as follows [14]:

Hardness [HB] Yield limits [MPa] Tensile stress [MPa] max x j ( i ) − xi ( i )

388 1375 1170 x*j ( i ) = , (2)
max x j ( i ) − min x j ( i )

where x0* ( i ) , ∆ 0 j ( i ) , x*j ( i ) are reference sequence,

2 RESULTS
deviation sequence and comparability sequence,
respectively.
MR is the measure of machinability of the material.
Hence, for a characteristic like MR, “larger-the-better” ∆ 0 j ( i ) = x0* ( i ) − x*j ( i ) . (3)

Table 3. L18 orthogonal array

Range of factors
Experiment Actual value of parameters
A B C D
No.
I V ton [µs] toff [µs] MR [mm/min] TWR [g/min] OC [mm] TOC [mm]
1 1 1 1 1 0.019137 0.00261 0.2419 0.04839
2 1 2 2 2 0.042738 0.00466 0.1630 0.06966
3 1 3 3 3 0.065654 0.00205 0.1978 0.03706
4 2 1 1 2 0.056586 0.00351 0.1885 0.05388
5 2 2 2 3 0.049971 0.00410 0.1328 0.03871
6 2 3 3 1 0.062078 0.00317 0.1398 0.04179
7 3 1 2 1 0.090978 0.00905 0.1398 0.01508
8 3 2 3 2 0.051362 0.00366 0.1143 0.06070
9 3 3 1 3 0.072961 0.00675 0.0911 0.04752
10 1 1 3 3 0.044799 0.00371 0.1398 0.03871
11 1 2 1 1 0.039450 0.00436 0.1027 0.04284
12 1 3 2 2 0.032244 0.00559 0.1444 0.04806
13 2 1 2 3 0.081764 0.00526 0.1537 0.03786
14 2 2 3 1 0.050321 0.00456 0.1491 0.05987
15 2 3 1 2 0.043268 0.00399 0.1003 0.04493
16 3 1 3 2 0.070008 0.00488 0.1676 0.06497
17 3 2 1 3 0.062579 0.00699 0.1235 0.11196
18 3 3 2 1 0.081983 0.00456 0.1769 0.09516

Analysis of EDM Process Parameters on Inconel 718 Using the Grey-Taguchi and Topsis Methods 559
 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

Similarly, other computation was carried out ∆ min + ζ ⋅ ∆ max

for 18 experiments and the values of all Δ0j for ξ j (i ) = , (4)
∆ 0 j ( k ) + ζ ⋅ ∆ max
j = 1, 2, 3, …, 18 are represented in Table 4.
where ζ is a unique coefficient and ζ is considered as
In continuation of data preprocessing, a 0.5 because all parameters are given equal weight.
coefficient for grey relational analysis is found using The grey relational grade (GRG) presented in
the relation given below [14]: Table 5 is calculated by averaging the GRC and overall

Table 4. Performance characteristics of the processed data

Experiment Performance characteristics after data processing Deviation sequences
run reference MR TWR OC TOC MR TWR OC TOC
sequence [mm/min] [g/min] [mm] [mm] [mm/min] [g/min] [mm] [mm]
1 0.0000 0.9197 0.0000 0.6562 1.0000 0.0803 0.0000 0.3438
2 0.3285 0.6270 0.5231 0.4366 0.6715 0.3730 0.5231 0.5634
3 0.6475 1.0000 0.2924 0.7731 0.3525 0.0000 0.2924 0.2269
4 0.5213 0.7921 0.3539 0.5995 0.4787 0.2079 0.3539 0.4005
5 0.4292 0.7069 0.7231 0.7561 0.5708 0.2931 0.7231 0.2439
6 0.5977 0.8399 0.6769 0.7243 0.4023 0.1601 0.6769 0.2757
7 1.0000 0.0000 0.6769 1.0000 0.0000 1.0000 0.6769 0.0000
8 0.4486 0.7697 0.8462 0.5291 0.5514 0.2303 0.8462 0.4709
9 0.7492 0.3289 1.0000 0.6652 0.2508 0.6711 1.0000 0.3348
10 0.3572 0.7634 0.6769 0.7561 0.6428 0.2366 0.6769 0.2439
11 0.2827 0.6695 0.9231 0.7135 0.7173 0.3305 0.9231 0.2865
12 0.1824 0.4937 0.6462 0.6596 0.8176 0.5063 0.6462 0.3404
13 0.8718 0.5416 0.5846 0.7649 0.1282 0.4584 0.5846 0.2351
14 0.4341 0.6418 0.6154 0.5377 0.5659 0.3582 0.6154 0.4623
15 0.3359 0.7221 0.9385 0.6919 0.6641 0.2779 0.9385 0.3081
16 0.7081 0.5952 0.4923 0.4851 0.2919 0.4048 0.4923 0.5149
17 0.6047 0.2939 0.7846 0.0000 0.3953 0.7061 0.7846 1.0000
18 0.8748 0.6418 0.4308 0.1734 0.1252 0.3582 0.4308 0.8266

Table 5. Computed Grey relational grade

GRC Grey relational grade (GRG)
Experiment No.
MR ξi(1) TWR ξi(2) OC ξi(3) MR ξi(4) yi = 1/4 · (ξi(1) + ξi(2) + ξi(3) + ξi(4))
1 0.3333 0.8617 1.0000 0.5926 0.6969
2 0.4268 0.5727 0.4887 0.4702 0.4896
3 0.5865 1.0000 0.6310 0.6879 0.7263
4 0.5109 0.7063 0.5856 0.5552 0.5895
5 0.4669 0.6304 0.4088 0.6722 0.5446
6 0.5542 0.7574 0.4248 0.6446 0.5952
7 1.0000 0.3333 0.4248 1.0000 0.6895
8 0.4755 0.6847 0.3714 0.5150 0.5117
9 0.6660 0.4270 0.3333 0.5989 0.5063
10 0.4375 0.6788 0.4248 0.6722 0.5533
11 0.4108 0.6020 0.3514 0.6357 0.5000
12 0.3795 0.4969 0.4362 0.5949 0.4769
13 0.7959 0.5217 0.4610 0.6802 0.6147
14 0.4691 0.5826 0.4483 0.5196 0.5049
15 0.4295 0.6428 0.3476 0.6188 0.5097
16 0.6314 0.5526 0.5039 0.4927 0.5451
17 0.5585 0.4146 0.3892 0.3333 0.4239
18 0.7997 0.5826 0.5372 0.3769 0.5741

560 Thangavel, Y. – Paramasivam, S.

 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

assessment of the multiple objective optimization Moreover, Fisher’s test (F test) is also performed
determined using Eq. (5). to establish machining parameters’ influence on the
1 b performance characteristic [17]. ANOVA for GRG
γj = ∑χi ( a ) ,
b a =1
(5) is presented in Table 7. Based on the ANOVA, table
voltage and pulse off-time show a higher percentage
where γj is the GRG of jth experiment and b is the contribution, hence voltage and pulse off-time are
number of performance characteristics. dominant parameters that affect the MR, TWR, OC
and TOC. In EDM, increase voltage increase the
3 DISCUSSION current required for machining which improves the
ionization effect between the tool and electrode. This
The multi-response performance index presented in
ionization effect increases the temperature of the
Table 6 presents the average value of the GRG for
tool and electrode, resulting in melting of workpiece
every level. The highest value of GRG indicates the
material. The molten material resulted from heating is
best possible level of the process parameters. The
calculated higher GRG value indicates the closeness evaporated during pulse off time of the EDM process.
to the optimal value. The total mean of the GRG for Hence, the voltage and pulse off-time are considered
the eighteen runs was estimated and is presented as significant factors in EDM.
in Table 6. The optimal parameter combination for
better MR and lesser TWR, OC and TO is found to be Table 7. ANOVA table
(A1B1C3D1) as given in Table 6. Factors DoF SS MSj F ratio φ
I 2 0.003 0.0016 0.2931 2.72
Table 6. Multi response performance index V 2 0.042 0.0214 4.056 37.71
Symbol Level 1 Level 2 Level 3 Main effect (max-min) ton 2 0.004 0.002 0.3841 3.57
A 0.5738 0.5598 0.5418 0.0321 toff 2 0.016 0.008 1.521 14.14
B 0.6148 0.4958 0.5648 0.1191 Error 9 0.047 0.0053 41.84
C 0.5377 0.5649 0.5728 0.0351 Total 17 0.113 0.0067 100
D 0.5934 0.5204 0.5615 0.0730
yi = = 0.5585
3.2 Confirmation Test

3.1 ANOVA Confirmation tests were performed to show the

improvement of performance characteristics [14]. The
The influence of process parameter on the performance calculated GRG (I) is calculated as shown below:
characteristic was analyzed using analysis of variance
q
(ANOVA). The effect of process parameters is
measured by the sum of the squared deviations. It η = ηm + ∑ (ηi − ηm ), (8)
i =1
predicts˝the influential process parameter on output
performance. The total sum of the squared deviations
where ηm is the total mean of the GRG, q is the
(SSD) from the total mean of the GRG yi can be
number of significant parameters; ηi is the mean of the
calculated as:
GRG at the optimal level. The predicted MR, TWR
p
OC and TOC overcut and GRG for the best possible
SS D = ∑ ( γ j −γ i ) .
2
(6)
j =1 machining factors are estimated using the Eq. (8).
In which, p is the number of experiments in Based on the confirmation test, GRG has improved by
the OA and γj is the mean of the GRG for the jth 0.0153 from the initial level; hence, as a whole, the
experiment. performance of EDM process has been improved.
The sum of the squares (SS) calculated is divided
by degrees of freedom (DoF) to obtain mean square 3.3 TOPSIS
of a factor (MSj) or error (MSe). The percentage
contribution (φ) of each of the design parameters is The TOPSIS method is used to find an ideal solution,
obtained using the Eq. (7) [14]. and the following steps are followed to find the
ss j optimal parameter combination [18].
ϕj = . (7)
ssT
Analysis of EDM Process Parameters on Inconel 718 Using the Grey-Taguchi and Topsis Methods 561
 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

Step 1: The decision matrix consists of ‘n’ Step 7: the Pi values (preference value) are ranked
attributes and ‘m’ alternatives, and it is represented in in descending order to find the optimal parameters
Eq. (9). combination.

 T11 T12 ... T1n  3.4 TOPSIS Analysis

T T22 ... T1n 
A =  21 . (9) The four responses such as MR, TWR, OC and TOC
     
  are normalized using the Eq. (10). In this analysis, the
Tm1 Tm 2 ... Tmn  weight criterion for MR, TWR, OC and TOC are
Here Tij is the performance of ith alternative with 0.2154, 0.0177, 0.5644 and 0.2026, respectively. The
respect to jth attribute. relative normalized weight matrix has been computed
using the proper weight criteria. The weight criteria
Step 2: Using Eq. (10), normalize decision matrix are multiplied to obtain the normalized weighted
values were found. matrix using Eq. (11). The ideal and the negative ideal
solutions are calculated from the normalized weighted
Tij matrix table; that is, VMR
+
= 0.0778, VMR
−
= 0.0164, VTWR
+
rij = , j = 1, 2,, n. (10)
m = 0.0077, VTWR = 0.0002, VOC = 0.5417, VOC = 0.2040,
− + −

∑T
i =1
2
ij
+
VTOC = 0.0900 and VTOC −
= 0.0121. The separation
measures of each condition from the ideal and
negative ideal solutions were computed with Eqs. (14)
Step 3: Weight for each response are calculated,
and (15). Finally, the relative closeness coefficient
and the associated weights are multiplied with
(CC) value for each combination of factors of EDM
normalized decision matrix to obtain the weighted
process is calculated using Eq. (16), which is shown
normalized decision matrix. The weighted normalized
in Table 8. It is evident from Table 1 that experiment
decision matrix is obtained as:
No. 1 is the best experiment and experiment No. 3 is
Rij = Mi × rij, (11) second best alternative. According to this result, it is
recommended to choose experiment No. 1, which has
where i = 1, ..., m and j = 1, ..., n. Mj represents the the highest proximity coefficient value among
weight of the jth attribute or criteria. alternative experiments. Thus, it is evident from the
Step 4: Positive ideal solution (PIS) and negative TOPSIS analysis that the combination of process
ideal solution (NIS) are determined as follows: parameters such as 10 A, 30 V, 100 µs and 20 µs is
suitable for the best EDM performance measures.
N+ = (n1+, n2+, ..., nx+) maximum values, (12) On comparing the grey-Taguchi and TOPSIS
N– = (n1–, n2–, ..., nx–) minimum values. (13) method results, the best level for I, V and toff are 10
A, 30 V and 20 µs. Based on these results, the pulse
Step 5: The separation of each alternative from on time shows two optimal levels, 100 µs and 200 µs,
respectively. Although the levels for pulse on time
positive ideal solution (PIS) is calculated as:
are different, it will not have any significant impact
n on the performance since the contribution of pulse
∑ (T − x +j ) , i = 1, 2,..., m.
2
α i+ = ij (14) on time is very minimal, as shown in ANOVA Table
j =1 7. Hence, based on the results, it is clear that both
these approaches are viable for arriving at the optimal
The separation of alternatives form the negative- process parameter combination with the available
ideal solution is expressed in Eq. (15). sparse data.
n

∑ (T − x −j ) , i = 1, 2,..., m. 3.5 Analysis of Tool Wear

2
α i− = ij (15)
j =1

The tool electrode is the important factor which

Step 6: Eq. (16) is used to find the relative decides the shape accuracy of the drilled hole. In order
proximity of the different alternative to the ideal to understand the tool wear behaviour, experiments
solution. are conducted by varying one parameter at a time.
α− Based on Table 7, the voltage is the most influential
Pi = + i − , i = 1, 2,..., m. (16)
αi + αi parameters. Hence, the voltage is varied by keeping
562 Thangavel, Y. – Paramasivam, S.
 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

Table 8. Normalized data, weighted normalized data, separation measures and closeness coefficient values
Closeness
Experiment Normalized data Weighted normalized data Separation measures
coefficient
No.
MR TWR OC TOC MR TWR OC TOC α � i+ α � i− Pi
1 0.0759 0.0104 0.9598 0.1920 0.0164 0.0002 0.5417 0.0389 0.0802 0.3644 0.8196
2 0.1696 0.2235 0.6467 0.2764 0.0365 0.0039 0.3650 0.0560 0.1846 0.2062 0.5276
3 0.2605 0.0983 0.7848 0.1470 0.0561 0.0017 0.4429 0.0298 0.1178 0.2599 0.6881
4 0.2245 0.1684 0.7479 0.2138 0.0484 0.0030 0.4221 0.0433 0.1318 0.2516 0.6563
5 0.1983 0.1967 0.5269 0.1536 0.0427 0.0035 0.2974 0.0311 0.2538 0.1161 0.3138
6 0.2463 0.1521 0.5547 0.1658 0.0531 0.0027 0.3130 0.0336 0.2368 0.1365 0.3657
7 0.3610 0.4341 0.5547 0.0598 0.0778 0.0077 0.3130 0.0121 0.2415 0.1254 0.3417
8 0.2038 0.1756 0.4535 0.2408 0.0439 0.0031 0.2559 0.0488 0.2907 0.0955 0.2473
9 0.2895 0.3238 0.3614 0.1885 0.0624 0.0057 0.2040 0.0382 0.3420 0.0724 0.1747
10 0.1777 0.1780 0.5547 0.1536 0.0383 0.0031 0.3130 0.0311 0.2394 0.1303 0.3524
11 0.1565 0.2091 0.4075 0.1700 0.0337 0.0037 0.2300 0.0344 0.3197 0.0537 0.1439
12 0.1279 0.2681 0.5729 0.1907 0.0276 0.0047 0.3233 0.0386 0.2299 0.1465 0.3892
13 0.3244 0.2523 0.6098 0.1502 0.0699 0.0045 0.3442 0.0304 0.2065 0.1684 0.4493
14 0.1997 0.2187 0.5916 0.2375 0.0430 0.0039 0.3339 0.0481 0.2148 0.1686 0.4397
15 0.1717 0.1914 0.3979 0.1783 0.0370 0.0034 0.2246 0.0361 0.3242 0.0533 0.1412
16 0.2778 0.2341 0.6650 0.2578 0.0598 0.0041 0.3753 0.0522 0.1716 0.2169 0.5583
17 0.2483 0.3353 0.4900 0.4442 0.0535 0.0059 0.2765 0.0900 0.2662 0.1596 0.3747
18 0.3253 0.2187 0.7019 0.3776 0.0701 0.0039 0.3961 0.0765 0.1464 0.2639 0.6431

a) b) c)
Fig. 2. SEM micrographs; a) 30 V, 14 A, 200 µs and 40 µs, b) 40 V, 14 A, 200 µs and 40 µs, c) 50 V, 14 A, 200 µs and 40 µs

the other parameters such I, ton, and toff constant. 4 CONCLUSIONS

The voltage value is varied as 30 V, 40 V, 50 V by
keeping the I, ton, and toff at 14 A, 200 µs, and 40 Machining characteristic optimization of EDM for
µs, respectively. Each experiment is repeated once. Inconel 718 is preformed using grey-Taguchi method.
Based on the SEM micrograph, which is shown in The optimal machining parameters were found using
Fig. 2, it is evident that the wear pattern varies with GRG for multi-performance characteristics. Eighteen
experimental runs based on OA have been performed.
the voltage. It is evident from Fig. 2 that the recast
The optimal combination of input parameter to
layer pattern observed around the circumference of
acquire better responses based on grey-Taguchi has
the hole varies with voltage. It is due to the fact that
been found to be I (10 A), V (30 V), ton (200 µs) and
tool wear on the electrode is not even and, hence, the toff (20 µs). According to ANOVA, the voltage and
uneven electrode face will have different proximity toff plays a prominent role in machining Inconel 718.
towards the workface, resulting in uneven recast layer The confirmation test result proves that there is a
on the circumference of the hole. Further studies are notable improvement in the GRA value from 0.6969
required to understand the tool wear behaviour when to 0.7122, when machining is done with the optimal
machining Inconel 718. parametric combination. Based on the confirmation
Analysis of EDM Process Parameters on Inconel 718 Using the Grey-Taguchi and Topsis Methods 563
 Strojniški vestnik - Journal of Mechanical Engineering 65(2019)10, 557-564

test, it is evident that GRA may be applied with sparse of Materials Engineering and Performance, vol. 21, no. 6, p.
data in manufacturing industries to optimize the EDM 882-891, DOI:10.1007/s11665-011-9962-8.
process parameters to be competitive in the market. [8] Kuppan, P., Rajadurai, A., Narayanan, S. (2008). Influence
The best combinations identified using the TOPSIS of EDM process parameters in deep hole drilling of Inconel
718. The International Journal of Advanced Manufacturing
method for better performance measures is 10 A, 30 V,
Technology, vol. 38, no. 1-2, p. 74-84, DOI:10.1007/s00170-
100 µs and 20 µs. These multi-objective optimization
007-1084-y.
techniques are found to be suitable for optimizing [9] Mohanty, A., Talla, G., Gangopadhyay, S. (2014). Experimental
the EDM process parameter. Tool wear behaviour investigation and analysis of EDM characteristics of Inconel
is also studied through SEM images by varying the 825. Materials and Manufacturing Processes, vol. 29, no. 5,
voltage. The SEM micrographs confirm that the wear p. 540-549, DOI:10.1080/10426914.2014.901536.
pattern varies with the voltage. Hence detail analysis [10] Mohanty, C.P.,Satpathy, M.P., Mahapatra, S.S., Singh, M.N.
and optimization of electrical parameters may be (2018). Optimization of cryo-treated EDM variables using
considered as future work. TOPSIS-based TLBO algorithm. Sadhana, vol. 43, no. 51,
DOI:10.1007/S12046-018-0829-7.
5 REFERENCES [11] Dang, X.P. (2018).Constrained multi-objective optimization
of EDM process parameters using kriging model and particle
swarm algorithm. Materials and Manufacturing Processes,
[1] Shen, Y., Liu, Y., Dong, H., Zhang, K., Lv, L., Zhang, X., Wu,
vol. 33, no. 4, p. 397-404, DOI:10.1080/10426914.2017.129
X., Zheng, C., Ji, R. (2017). Surface integrity of Inconel
2037.
718 in high-speed electrical discharge machining milling
[12] Lin, M.-Y., Tsao, C.-C., Hsu, C.-Y., Chiou, A.-H., Huang, P.-C.,
using air dielectric. The International Journal of Advanced
Manufacturing Technology, vol. 90, no. 1-4, p. 691-698, Lin, Y.-C. (2013). Optimization of micro milling electrical
DOI:10.1007/s00170-016-9332-7. discharge machining of Inconel 718 by Grey-Taguchi method.
[2] Talla, G., Gangopadhyay, S., Biswas, C.K. (2016). Effect of Transactions of Nonferrous Metals Society of China, vol. 23,
powder-suspended dielectric on the EDM characteristics no. 3, p. 661-666, DOI:10.1016/S1003-6326(13)62513-3.
of Inconel 625. Journal of Materials Engineering and [13] Muthuramalingam, T., Mohan, B. (2013). Taguchi-grey
Performance, vol. 25, no. 2, p. 704-717, DOI:10.1007/s11665- relational based multi response optimization of electrical
015-1835-0. process parameters in electrical discharge machining. Indian
[3] Talla, G., Gangopadhyay, S., Biswas, C.K. (2017). Influence Journal of Engineering & Materials Science, vol. 20, no. 6, p.
of graphite powder mixed EDM on the surface integrity 471-475.
characteristics of Inconel 625. Particulate Science and [14] Lin, M.Y., Tsao, C.C., Huang, H.H., Wu, C.Y., Hsu, C.Y.
Technology: An International Journal, vol. 35, no. 2, p. 219- (2015). Use of the grey-Taguchi method to optimise the
226, DOI:10.1080/02726351.2016.1150371. micro-electrical discharge machining (micro-EDM) of Ti-
[4] Dhanabalan, S., Sivakumar, K., Sathiya Narayanan, C. 6Al-4V alloy. International Journal of Computer Integrated
(2014). Analysis of form tolerances in electrical discharge Manufacturing, vol. 28, no. 6, p. 569-576, DOI:10.1080/095
machining process for Inconel 718 and 625. Materials 1192X.2014.880946.
and Manufacturing Processes, vol. 29, no. 3, p. 253-259, [15] Deng, J.L. (1982). Control problems of grey systems. System &
DOI:10.1080/10426914.2013.852213. Control Letters, vol. 1, no. 5, p. 288-294, DOI:10.1016/S0167-
[5] Torres, A., Luis, C.J., Puertas, I. (2015). Analysis of the 6911(82)80025-X.
influence of EDM parameters on surface finish material [16] Nalbant, M., Altın, A., Gökkaya, H. (2007). The effect of cutting
removal rate and electrode wear of an Inconel 600 alloy. The speed and cutting tool geometry on machinability properties of
International Journal of Advanced Manufacturing Technology, nickel-base Inconel 718 super alloys. Materials & Design, vol.
vol. 80, no. 1-4, p. 123-140, DOI:10.1007/s00170-015-6974-9. 28, no. 4, p. 1334-1338, DOI:10.1016/j.matdes.2005.12.008.
[6] Tanjilul, M., Ahmed, A., Senthil Kumar, A., Rahman, M. (2018). [17] Fisher, R.A. (1925). Statistical Methods for Research Worker,
A study on EDM debris particle size and flushing mechanism Oliver & Boyd, London.
for efficient debris removal in EDM-drilling of Inconel 718. [18] Ramesh, S., Viswanathan, R., Ambika, S. (2016).
Journal of Materials Processing Technology, vol. 255, p. 263- Measurement and optimization of surface roughness and
274, DOI:10.1016/j.jmatprotec.2017.12.016. tool wear via grey relational analysis, TOPSIS and RSA
[7] Rajesha, S., Sharma, A.K., Kumar, P. (2012). On electro techniques. Measurement, vol. 78, p. 63-72, DOI:10.1016/j.
discharge machining of Inconel 718 with hollow tool. Journal measurement.2015.09.036.

564 Thangavel, Y. – Paramasivam, S.