coatings

Article
Optimization of Wire EDM Process Parameters on Cutting
Inconel 718 Alloy with Zinc-Diffused Coating Brass Wire
Electrode Using Taguchi-DEAR Technique
Lijun Liu 1 , Muthuramalingam Thangaraj 2, * , Panagiotis Karmiris-Obratański 3, * , Yuanhua Zhou 4, *,
Ramamurthy Annamalai 5 , Ryszard Machnik 3 , Ammar Elsheikh 6 and Angelos P. Markopoulos 7

1 School of Mechanical Engineering, Xijing University, Xi’an 710123, China

2 Department of Mechatronics Engineering, SRM Institute of Science and Technology, SRM Nagar,
Kattankulathur 603203, India
3 Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of
Science and Technology, 30-059 Cracow, Poland
4 School of Mechanical Engineering, Yangtze University, Jingzhou 434023, China
5 Department of Mechanical Engineering, Bharath Institute of Higher Education and Research, Tambaram,
Chennai 600073, India
6 Department of Production Engineering and Mechanical Design, Faculty of Engineering, Tanta University,
Tanta 31527, Egypt
7 Laboratory of Manufacturing Technology, School of Mechanical Engineering, National Technical University of
Athens, 15780 Athens, Greece
* Correspondence: muthurat@srmist.edu.in (M.T.); karmiris@agh.edu.pl (P.K.-O.);
zhouyuanhua@yangtzeu.edu.cn (Y.Z.)

Citation: Liu, L.; Thangaraj, M.; Abstract: Inconel 718 alloy has a wide range of applications in the aerospace sector because of its
Karmiris-Obratański, P.; Zhou, Y.; superior mechanical properties and its weldability. The machining of such higher strength materials
Annamalai, R.; Machnik, R.; Elsheikh, with complex shapes is possible with wire electrical discharge machining. In the present research,
A.; Markopoulos, A.P. Optimization an endeavor was made to enhance the machining process by utilizing zinc-diffused coating brass
of Wire EDM Process Parameters on wire electrode and Taguchi-Data Envelopment Analysis-based Ranking (DEAR) methodology in the
Cutting Inconel 718 Alloy with
process while machining Inconel 718 alloy. Material removal rate, kerf width, and surface roughness
Zinc-Diffused Coating Brass Wire
were considered as the quality measures. The optimal arrangement of input factors in the Wire
Electrode Using Taguchi-DEAR
Electrical Discharge Machining (WEDM) process were found as 140 µs (Ton ), 50 µs (Toff ), 60 V (SV),
Technique. Coatings 2022, 12, 1612.
and 5 kg (WT) among the elected factors with the error accuracy of 1.1%. The pulse-off time has the
https://doi.org/10.3390/
coatings12111612
most significance on formulating the quality measures owing to its importance on deionization in
the process.
Academic Editor: Alessandro Latini

Received: 16 September 2022 Keywords: Inconel 718 alloy; DWE; DEAR; optimization; WEDM
Accepted: 20 October 2022
Published: 23 October 2022

Publisher’s Note: MDPI stays neutral

1. Introduction
with regard to jurisdictional claims in
published maps and institutional affil- Even though nickel super alloys are classified as difficult-to-cut materials, they have
iations. gained popularity based on their excellent mechanical properties in increased temperatures,
including creep, fatigue, and corrosion resistance [1,2]. Thus, several industries use nickel-
based alloys, including aerospace, nuclear, automotive, and chemical [3]. Nickel-based
alloys such as Face Cantered Cubic (FCC) Structures are becoming increasingly important
Copyright: © 2022 by the authors. due to their ability to format Topological Close Packed (TCP) phases, which is the largest
Licensee MDPI, Basel, Switzerland. group of intermetallic compounds with complex crystallographic structures [4]. These
This article is an open access article phases increase their strength and can withstand temperatures up to 1500 ◦ C [5]. Since
distributed under the terms and nickel-based alloys are difficult-to-cut materials, the manufacturing cost of conventional
conditions of the Creative Commons
machining is increased [6]. This may dramatically challenge the economic feasibility of the
Attribution (CC BY) license (https://
machining process due to their abrasive nature and the increased mechanical properties,
creativecommons.org/licenses/by/
which may lead to excessive cutting forces, tool wear, and temperatures [7]. Thus, as a
4.0/).

Coatings 2022, 12, 1612. https://doi.org/10.3390/coatings12111612 https://www.mdpi.com/journal/coatings

Coatings 2022, 12, 1612 2 of 13

cost-effective solution using unconventional machining methods such as the Wire Electrical
Discharge Machining (WEDM) process, the exotic materials can be machined with the
ability to produce complicated shapes [8]. WEDM removes the material by melting and
vaporizing cavities using electric discharges that come from a scrolling electrical wire. Dur-
ing machining, the inter-electrode gap is flushed with a dielectric under a certain pressure,
which removes erosion products in the machining zone, provides the appropriate condi-
tions necessary for electrical erosion to occur, and insulates and cools the electrodes [9,10].
The dielectric is usually demineralized and deionized water, and the electrode is brass or
copper wire with a zinc jacket. WEDM is a variation of EDM machining, where the main
difference is the type of working electrode used. WEDM wire cutting is the most precise
method of metal cutting, allowing dimensional accuracy much higher than laser cutting
(thermal cutting) [11].
Electrical discharges have been established to affect the surface integrity of work pieces
for many years [12,13]. Several studies have shown that the roughness of the surface of
wire-EDM varies with the duration of the current pulse (Ton ) [14–16], the peak discharge
current (Ip ) [17–20], and the average energy per spark [21,22]. Using a Response Surface
Methodology (RSM), a mathematical model was proposed in order to evaluate the WEDM
process parameters during the machining of Inconel 627 alloy [23]. Based on their results,
the Material Removable Rate (MRR) can be increased up to 85% as the pulse-on time
is increased, but we can achieve the same result by decreasing the pulse-off time. The
dimensional accuracy of machining Inconel 718 by WEDM and producing fir tree slots
were investigated [24]. By using nickel-coated electrodes, the authors tried to avoid the
contamination of the workpiece and the possibility of creating intermetals. Using the
composite electrodes, the machining time was reduced by 33%, but the standard brass
wire electrodes produced better surface roughness. There are a lot of publications focused
on the formation of the recast layer [25–28], and the surface crack density [29,30]. The
formation of the recast layer on Inconel 718 using a vibration-assisted WEDM was also
investigated [31]. The results revealed that within 15 to 20 µm of the wire-EDM cut surface,
residual stresses changed from tensile to compressive and the recast layer thickness formed
between 5 to 9 µm. Another study investigated the surface integrity and performance of
WEDM cutting an Inconel 718 using coated and uncoated electrodes [32]. It was observed
that by analyzing the variables, i.e., recast layer characteristics, wire feed rate, and kerf
width, the zinc-coated copper electrodes have higher performance compared to the brass
wire. More specifically, using the optimal machining parameters, the zinc-coated copper
wire feed rate was increased by 35% while the wire consumption was reduced by 40%.
Utilizing the same nickel alloy, the wire material performance in the productivity and
surface integrity of the workpiece machined by WEDM was analyzed [33]. The authors
have drawn several conclusions from the current study, particularly, that the discharge
energy significantly influenced surface roughness and cutting speed, and when discharge
energy mode was changed from the highest to the lowest, surface roughness was reduced
by 46.9%. Additionally, the coating of the wire electrodes reduced the cutting time by
22%. Finally, extensive investigation of the WEDM process on precision machining of
Nimonic C 236 alloy was performed [34]. The authors performed a detailed analysis of
the machined surface by using Scanning Electron Microscopy (SEM) and Transmission
Electron Microscopy (TEM). The results revealed that there was a diffusion process between
the electrode material and the workpiece, in particular, an adhesive film of 15 wt.% Cu
and 2 wt.% Zn adheres to the subsurface and surface of the sample. It was observed
that zinc-diffused brass wire electrodes can produce better machinability in the WEDM
process [35]. However, the implementation of optimization algorithms is important for
enhancing the process mechanism [36].
As it can be seen from the above-mentioned literature review, there are limited studies
that perform an optimization study of Inconel alloys and especially of the Inconel 718,
by using a coated electrode. More specifically, in the present study, there is an extensive
analysis of the occurred mechanisms during the machining and the relationship between the
Coatings 2022, 12, 1612 3 of 13

electrode conductivity and the machining performance. Although many research attempts
are available on the machining of nickel-based alloy specimens, only a few research works
were available to examine the influence of process control factors on quality measures
while cutting this kind of alloy using the WEDM process. Only a few research endeavors
were made to adopt Taguchi-DEAR as a Multi-Response Optimization Techniques (MCDT)
method in the WEDM process. Hence, this experimental investigation is carried out to
employ this method to optimize the WEDM cutting of chosen specimens to achieve the
following goals:
• Employing Taguchi-DEAR method as a new MCDT tool to obtain optimal arrangement
of process control factors of the machining process.
• Analyzing the influence of process control factors in WEDM process using different
performance measures.
• To identify the most significant factors in performance measures.

2. Experiments and Methods

2.1. Selection of Workpiece Specimens and Wire Electrodes
In the present study, the utilized material was an Inconel 718 nickel-based alloy
(Bibus Metals, Krakow, Poland). Inconel 718 has a wide range of applications in the
aerospace sector because of its superior mechanical properties and its weldability, and it is
a nickel-ferrous-chromium-based super alloy capable of withstanding temperatures up to
650 ◦ C [37]. Due to the γ prime and γ double prime phases, the Inconel 718 alloy achieves
high thermal strength [38]. Thus, this alloy is extensively used for gas turbine blades [39].
In order to achieve its strength, refractory alloying elements are added to achieve the
well-known γ austenite nickel solid solution. Typical workpieces are rectangular specimens
(10 mm × 10 mm × 25 mm) with a dimension of 10 mm × 10 mm and a length of 25 mm
to be used as workpiece specimens.
The selection of wire electrode material plays an important role in the WEDM process.
Due to their superior physical properties as depicted in Table 1, zinc-diffused brass wire
electrode (DWE) was utilized as tool electrodes with a diameter of 0.25 mm. The following
Table 2 contains the chemical composition of the Inconel 718 alloy using X-ray fluorescence
spectroscopy (XRF) manufactured by Bruker Corporation, Massachusetts, United States.
Figure 1 shows the diffused wire electrodes for machining the workpiece in the WEDM
process. The brass wire electrode coated with a zinc layer of 25 µm thickness was used
as coating thickness to reduce electrode wear and wire breakage [40]. The zinc-coated
brass wire electrode was treated with heat for making the coated zinc to melt and attach
tightly to the brass wire electrode [41]. Figure 1 shows that the zinc material was uniformly
distributed around the brass wire electrode. The three-dimensional views of the machined
surface wire electrode were acquired using Atomic Force Microscope (AFM), manufactured
by NTEGRA PRIMA, Amsterdam, The Netherlands. The quantification of morphology and
surface roughness can be crucial to formulate a quality control metric for the end product
or to verify a distinct processing step. It is essentially more critical to measure surface
roughness at the scale of microns. AFM has the ability to quantify three-dimensional spatial
resolutions. The AFM offers total 3D surface measurement by imaging topography-based
height analysis.

Table 1. Survey performed in the present study.

Conventional Diffused Zinc Coating

Properties Unit
Electrode Brass Electrode
Melting point ◦C 920 980
Tensile strength N/mm2 900 980
Coatings 2022, 12, 1612 4 of 13
Coatings 2022, 14, x FOR PEER REVIEW 4 of 13

Table 2. Chemical composition (wt.%) of the 718 alloy.

Table 2. Chemical composition (wt.%) of the 718 alloy.
C Mn Si Cr Ni Al Mo Cu Cb Ta Ti Co
0.05 0.08 0.1 C
18.25 Mn52.25 Si 0.54Cr Ni
2.9 Al0.03 Mo 5.19Cu Cb
0.01 Ta1.05 Ti 0.24Co
0.05 0.08 0.1 18.25 52.25 0.54 2.9 0.03 5.19 0.01 1.05 0.24

Figure1.1.WEDM
Figure WEDM process arrangement:
process arrangement:(a) (a)
Experimental setup;
Experimental (b) Zinc-diffused
setup; brass brass
(b) Zinc-diffused wire electrode,
wire elec-
and (c) Micro
trode, and (c)structure of wire electrode.
Micro structure of wire electrode.

2.2. WEDM Cutting of Inconel 718 Alloy Specimens

2.2. WEDM Cutting of Inconel 718 Alloy Specimens
In order to machine the specimens, an Electronica Sprintcut Electra ELPULS 40A
In order to machine the specimens, an Electronica Sprintcut Electra ELPULS 40A
WEDM machine (Electronica India Limted, Kolkata, India) has been used. Due to their im-
WEDM machine (Electronica India Limted, Kolkata, India) has been used. Due to their
portance on determining the machining characteristics, pulse-on time (Ton ), pulse-off time
importance on determining the machining characteristics, pulse-on time (Ton), pulse-off
(Toff ), servo voltage (SV), and wire tension (WT) are chosen as the input process parameters.
time (Toff), servo voltage (SV), and wire tension (WT) are chosen as the input process pa-
Pulse-on time is the duration of applying electrical energy between the workpiece and wire
rameters. Pulse-on time is the duration of applying electrical energy between the work-
electrode. Since the performance measures such as material removal rate (MRR), surface
piece and(R
roughness wire electrode. Since the performance measures such as material removal rate
a ), and kerf width (Kw ) influence the process efficiency, these parameters are
(MRR), surface
taken as the performanceroughnessmeasures
(Ra), andofkerf
thewidth
WEDM (Kwprocess
) influence thestudy.
in the process efficiency,
Deionized these
water
parameters
was used as theare insulating
taken as the performance
medium measuresmachining
for conducting of the WEDM
in theprocess in the study.
EDM process with
Deionized water was used as the insulating medium for conducting
a peak current of 16 Amps. The dielectric flow rate was chosen as 1, 2 MPa as constantmachining in the
EDM process
throughout with
all the a peak current
experiments with aofwire
16 Amps. The
feed rate asdielectric
4 m/min.flow rate was chosen
The consolidated as 1, 2
selection
MPa as constant throughout all the experiments
of process variables for this study is shown in Table 3. with a wire feed rate as 4 m/min. The
consolidated selection of process variables for this study is shown in Table 3.
Table 3. Influence of tool electrodes in the WEDM process.
Table 3. Influence of tool electrodes in the WEDM process.
Process Parameters Unit Variables
Process Parameters Unit Variables
Ton µs 100, 120, 150
Toff Ton µs µs 100, 120,
30, 40, 50150
SV Toff V µs 40, 60, 8050
30, 40,
WT SV kg V 5, 7,
40, 60,9 80
WT Kg 5, 7, 9
In order to calculate the MRR, for each test run, the weight was measured before
In order
and after to calculate using
the experiment the MRR, for eachscale.
a precision test run, the be
It can weight was by
denoted measured
3 mm/min. beforeThe
and
after the experiment using a precision scale. It can be denoted by 3 mm/min. The Ra of the
 Coatings 2022, 14, x FOR PEER REVIEW 5 of 13
Coatings 2022,
Coatings 14,12,
2022, x FOR
1612 PEER REVIEW 5 of5 of
13 13

machined specimen was evaluated by a non-contact surface roughness tester (TALYSURF

machined
Ra of thespecimen
machined was evaluated
specimen byevaluated
was a non-contact
by asurface roughness
non-contact tester
surface (TALYSURF
roughness tester
CCI LITE manufactured by Taylor Hobson Ltd, Leicester, UK) with high-pass filtering
(TALYSURF
CCI CCI LITE manufactured
LITE manufactured by Taylor Hobsonby Taylor
Ltd,Hobson
Leicester,Ltd.,
UK)Leicester, UK) with filtering
with high-pass high-pass
based on the ISO 4287 standard. The measurement was made in the perpendicular direc-
filtering
based based
on the ISOon the standard.
4287 ISO 4287 standard. The measurement
The measurement was madewas made
in the in the perpendicular
perpendicular direc-
tion to the cutting direction. The kerf width (Kw) of all machined specimens was meas-
direction
tion to the cutting
to the cutting direction.direction.
The kerfThe kerf(Kw)
width widthof (Kw) of all machined
all machined specimens specimens
was meas- was
ured using the Instron Tukon 2100B microscope from Wilson Instruments , MA, USA.
measured using the Instron Tukon 2100B microscope from Wilson
ured using the Instron Tukon 2100B microscope from Wilson Instruments , MA, USA. Instruments, MA, USA.
Figure 2 shows the measurement approach for kerf width. It was calculated by measuring
Figure
Figure 2 shows
2 shows the
the measurement
measurement approach
approach for
for kerf
kerf width.
width. It It
waswas calculated
calculated byby measuring
measuring
the
the distance
distance between
between the two edge lines made by the wire passage, as shown in Figure 2.
the distance between thethe two
two edge
edge lines
lines made
made byby
thethe wire
wire passage,
passage, as as shown
shown in in Figure
Figure 2. 2.
The
The surface
surface topography
topography of the machined surface was obtained using aaScanning Electron
The surface topography ofof the
the machined
machined surface
surface was
was obtained
obtained using
using Scanning
a Scanning Electron
Electron
Microscope
Microscope (SEM
(SEM S-3400N)
S-3400N) from Hitachi
fromHitachi Limited,
HitachiLimited, Ibaraki,
Limited,Ibaraki, Japan.
Ibaraki,Japan.
Japan.
Microscope (SEM S-3400N) from

Figure 2. Measurement of Kw of machined specimen using the microscope.

Figure 2. 2.
Figure Measurement of of
Measurement KwKof of
machined specimen
machined using
specimen thethe
using microscope.
microscope.
w
2.3. Taguchi—DEAR Technique
2.3.
2.3. Taguchi—DEARTechnique
Taguchi—DEAR Technique
Since the present study involves the four input factors with three levels and two-
Sincethe
Since thepresent
presentstudystudy involves the the four
fourinput
inputfactors
factorswith three
with levels
three levels andand
two-factor
two-
factor interactions between them, the L27 orthogonal array (OA) was selected for conduct-
interactions
factor between
interactions between them, the the
them, L27Lorthogonal
27 orthogonal array
array(OA)
(OA)was
wasselected
selectedfor forconducting
conduct-
ing experiments in the
experiments WEDM processaccording according to theTaguchi
Taguchitechnique
technique [42].[42]. Since the
ing experimentsininthe theWEDM
WEDMprocess process according to the Taguchi technique [42]. Sincethe
Since the
present
present investigation
investigation was
was performed
performed with
with three
three performance
performance measures,
measures, itit
waswas required
present investigation was performed with three performance was requiredto
required
toimplement
implement MCDT
MCDT ininthethe process.
process.
to implement MCDT in the process.
In the proposed DEAR approach,
approach, theoptimaloptimal levels of control factors can be com-
InInthe
theproposed
proposedDEARDEAR approach, the the optimallevelslevelsofofcontrol factors
control cancan
factors be be
computed
com-
puted using
usingusing a computed
a computed ratio depending
ratio ratio
depending on a certain
on a certain mapping mapping
processprocess
between between
a set ofaaoriginal
set of
puted a computed depending on a certain mapping process between set of
original
responses responses
and thisandand
ratio. this
This ratio. This
computed computed ratio
ratio is defined is defined as the Multi-Response-
original responses this ratio. This computed ratio isasdefined
the Multi-Response-Performance-
as the Multi-Response-
Performance-Index (MRPI) value to obtain the optimalofarrangement of the [43,44].
control Figure
factors
Performance-Index (MRPI) value to obtain the optimal arrangement factors
Index (MRPI) value to obtain the optimal arrangement the control of the control factors 3
[43,44]. Figure
illustrates 3 illustrates
the3steps involved the steps involved
in theinvolved in the analysis.
analysis.in the analysis.
[43,44]. Figure illustrates the steps

Stepsinvolved
Figure3.3.Steps
Figure involvedininTaguchi-DEAR.
Taguchi-DEAR.
Figure 3. Steps involved in Taguchi-DEAR.
Coatings 2022, 12, 1612 6 of 13

3. Results and Discussion

In the current work, 27 cutting trials were performed according to the proposed
design of experiments to examine WEDM parameters’ effects on workpiece specimens’
machinability. Each trial was conducted three times, and the average was considered
the final measured value. Table 4 lists the experimental outcome of all the conducted
trials. Totally, 81 trials were performed using the WEDM process to analyze the influence
of wire electrodes and process parameters on performance measures in such a process.
Figure 4 shows the microstructure analysis of machined specimens using DWE in the
WEDM process. The patterns of the wire electrodes are visible in specimens with a recast
white-layer region, craters and an arcing region.

Table 4. Calculation of performance measures in the WEDM.

Input Factors Quality Measures

Ton Toff SV WT MRR (mm3 /min) Ra (µm) KW (mm)
100 30 40 5 74.406 1.764 0.31
100 30 60 7 92.069 1.813 0.30
100 30 80 9 26.659 1.536 0.30
100 40 40 7 131.012 2.164 0.33
100 40 60 9 54.813 2.447 0.34
100 40 80 5 105.585 2.697 0.36
100 50 40 9 87.860 2.212 0.34
100 50 60 5 139.297 2.321 0.37
100 50 80 7 115.515 2.653 0.36
120 30 40 7 131.627 1.948 0.29
120 30 60 9 113.970 1.874 0.32
120 30 80 5 35.615 1.563 0.32
120 40 40 9 127.945 2.247 0.33
120 40 60 5 79.349 2.254 0.37
120 40 80 7 154.458 2.256 0.35
120 50 40 5 142.596 2.502 0.34
120 50 60 7 139.453 2.434 0.34
120 50 80 9 156.865 2.657 0.34
140 30 40 9 131.553 2.040 0.31
140 30 60 5 152.107 1.845 0.32
140 30 80 7 45.962 1.598 0.35
140 40 40 5 143.811 2.163 0.32
140 40 60 7 119.371 2.178 0.38
140 40 80 9 135.171 2.134 0.34
140 50 40 7 190.307 2.425 0.37
Coatings 2022, 14, x FOR PEER REVIEW 140 50 60 9 217.164 2.379 0.33
7 of 13
140 50 80 5 206.989 2.627 0.36

Figure 4. Machined surface of specimens in WEDM.

Figure 4. Machined surface of specimens in WEDM.
Coatings 2022, 12, 1612 7 of 13

Figure 4 shows the microstructure analysis of machined specimens using DWE in

the WEDM process. The patterns of the wire electrodes are visible with specimens with
a negligible recast-white layer region, craters and an arcing region. Figure 5 shows the
surface morphology of the machined specimen using the WEDM process with DWE under
trial 26. It shows the peak and valley over the machined surface. The white region indicates
the presence of the zinc content deliberated from the diffused wire electrode as per both
3D and 2D views of the surface. The zinc particles were deposited over the machined
surface. The surface roughness can also be interpreted from the two-dimensional view
of the surface. The histogram analysis shows a higher occurrence of surface roughness
over the machined surface. From the analysis, it is possible to analyze an average surface
roughness value from the higher occurrence of peaks and valleys of the machined surface
using the
Figure WEDM surface
4. Machined process.of specimens in WEDM.

Figure
Figure 5.
5. Surface
Surface morphology
morphology analysis
analysis of
of machined
machined specimen
specimen under
under the
the factors
factors of
of trial
trial 26:
26: (a)
(a) Three
Three
dimensional
dimensional view;
view; (b)
(b) Two dimensional view,
Two dimensional view, and
and (c)
(c) Histogram
Histogram analysis.
analysis.

3.1. Effects of Process Factors on Performance Measures

Table 5 shows the weights of each outcome parameter along with the MRPI values. It
was inferred that trial number 26 could remove more material with lower Ra and KW. The
material removal is directly proportional to the pulse-on time. Hence, the larger pulse-on
time could produce a higher MRR. Since the pulse-off time contributes for the deionization
process after the machining mechanism, the larger pulse-off time could produce lower
surface roughness. The servo voltage can highly contribute to the overcut [42]. The
Coatings 2022, 12, 1612 8 of 13

moderate servo voltage can produce lower kerf width. Hence, trial number 26 could
produce a higher MRR with lower surface roughness and kerf width over the machined
surface of workpiece specimens using the WEDM process with DWE.

Table 5. Calculation of weights and MRPI.

Weights
Trial No. MRPI
MRR Ra KW
1. 0.0229 0.0445 0.0399 18.7050
2. 0.0283 0.0433 0.0411 28.6394
3. 0.0082 0.0511 0.0411 2.4012
4. 0.0403 0.0363 0.0376 57.9910
5. 0.0169 0.0321 0.0365 10.1508
6. 0.0325 0.0291 0.0346 37.6650
7. 0.0270 0.0355 0.0365 26.0809
8. 0.0428 0.0338 0.0337 65.5571
9. 0.0355 0.0296 0.0346 45.0828
10. 0.0405 0.0403 0.0424 58.5362
11. 0.0350 0.0419 0.0387 43.8854
12. 0.0110 0.0502 0.0387 4.2856
13. 0.0393 0.0349 0.0376 55.3071
14. 0.0244 0.0348 0.0337 21.2726
15. 0.0475 0.0348 0.0355 80.6040
16. 0.0438 0.0314 0.0365 68.6989
17. 0.0429 0.0323 0.0365 65.7044
18. 0.0482 0.0295 0.0365 83.1364
19. 0.0404 0.0385 0.0399 58.4706
20. 0.0468 0.0425 0.0387 78.1695
21. 0.0141 0.0491 0.0355 7.1373
22. 0.0442 0.0363 0.0387 69.8744
23. 0.0367 0.0360 0.0329 48.1430
24. 0.0416 0.0368 0.0365 61.7309
25. 0.0585 0.0324 0.0337 122.3619
26. 0.0668 0.0330 0.0376 159.3354
27. 0.0636 0.0299 0.0346 144.7537

3.2. Computation of Significant Process Factors

In order to identify the optimal factors using the consolidated MRPI concept [43,44],
another combination of input process factors may provide better performance measures
than trial 26. The consolidated MRPI of all control variables with the corresponding
levels is shown in Table 6. The maximum-level value of each process factor specifies the
optimal level of input factors in formulating the quality measures. From Table 5, it was
inferred that Ton (level 3), Toff (level 3), SV (level 2), and WT (level 1) are the optimal
arrangement of process factors in the current investigation. The MRPI values with different
combinations of process control variables of the WEDM process were calculated using
the Taguchi-DEAR technique. The maximum value of each control variable indicates the
optimal level of input control variable of any machining process based on different quality
measures. It was inferred that the optimal arrangement of process control variables in
the process of the current study is 140 µs (Ton ), 50 µs (Toff ), 60 V (SV), and 5 kg (WT)
as shown in Table 7. The material removal is directly proportional to the pulse-on time.
Hence, the larger pulse-on time could produce a higher MRR [45]. Since the pulse-off time
contributes to the deionization process after the machining mechanism, the larger pulse-off
time could produce lower surface roughness. The shape of the wire electrode can highly
contribute to the overcut. The lower wire tension creates a smooth and straight wire which
has approached the specimens. Hence, it can produce a lower kerf width. The highest
value of max–min reveals the larger importance of process control variables on machining
characteristics. It was observed that pulse-off time has higher significance in determining
Coatings 2022, 12, 1612 9 of 13

the quality measures due to its importance on deionization [46]. The deionization has
to be performed after every pulse discharge. Then, only the next cycle of charging will
be effectively performed to enhance the process mechanism. Since the flushing process
performs during the pulse-off time, it can positively influence quality measures in the
WEDM process.

Table 6. Computation of average MRPI values.

Levels
Factors Max–Min
1 2 3
Ton 32.4748 53.4923 83.3307 50.8559
Toff 33.3589 49.1932 86.7457 53.3868
SV 49.6704 70.9961 48.6313 22.3648
WT 70.3756 51.9027 47.0196 23.3560

Table 7. Identification of optimum factors.

Factors Variable Unit

Pulse-on time 140 µs
Pulse-off time 50 µs
Servo voltage 60 V
Wire tension 5 kg

3.3. Confirmation of the Optimized Parameters

A confirmation trial needs to check the conclusions derived from the investigation. The
experimental trial was again performed using the optimal levels of significant factors [47].
The outcome values obtained from the confirmation experiments under the computed
setting are 218.234 mm3 /min (MRR), 2.345 µm (Ra ), and 0.31 mm (KW ). The DEAR
approach-based MRPI value of the confirmation experiment deviated by 1.1% from the
mean value. Hence, the accuracy of the prediction was verified.

3.4. Surface Analysis under Optimal Control Variables

As shown in Figure 6, the surface topography was investigated using AFM under the
optimal input factors in WEDM. The three-dimensional analysis showed that the lower
peaks and valleys were observed over the machined surface as compared with trial 26. The
histogram analysis proved that a higher occurrence of lower surface roughness points was
observed over the machined surface than the surface obtained with the process factors
of trial 26 in the WEDM process. Figure 7 shows the SEM-based surface morphology
under optimal factors in the WEDM process. The melted particles are resolidified over
the machined surface, which can be termed a white-layer thickness. The thickness of the
layer can affect the surface quality of the specimens [46]. It was observed that only a little
thickness of resolidified thickness was observed over the machined surface.
 Coatings 2022, 14, x FOR PEER REVIEW 10 of 13
Coatings 2022, 14, x FOR PEER REVIEW 10 of 13

Coatings 2022, 12, 1612 10 of 13

Figure Surface morphology

Figure6.6. Surface morphologyanalysis
analysisofofmachined
machinedspecimen
specimenunder
under optimal
optimal process
process factors:
factors: (a)
Figure
(a) 6. Surface morphology
Three-dimensional view analysis
and (b) of machined
Histogram specimen under optimal process factors: (a)
analysis.
Three-dimensional view and (b) Histogram analysis.
Three-dimensional view and (b) Histogram analysis.

Figure7.7.SEM-based
Figure SEM-basedsurface
surfacemorphology
morphologyunder
underoptimal
optimalfactors.
factors.
Figure 7. SEM-based surface morphology under optimal factors.
Coatings 2022, 12, 1612 11 of 13

4. Conclusions
In the current investigation, an effort was made to introduce Taguchi-DEAR methodol-
ogy in the WEDM process while machining Inconel 718 alloy using a zinc-diffused coating
brass wire electrode. The following conclusions were drawn from it:
â The zinc-diffused coating brass wire electrode can effectively machine the Inconel
718 alloy in the process.
â The patterns of the wire electrodes are visible with specimens with negligible recast
white-layer region, craters, and arcing region.
â The optimal arrangement of input factors in the WEDM process were found as 140 µs
(Ton ), 50 µs (Toff ), 60 V (SV), and 5 kg (WT) among the elected factors with the error
accuracy of 1.1%.
â The pulse-off time has the most significance on formulating the quality measures
owing to its importance on deionization in the process.
â The significance of other suitable coated electrodes can be analyzed on performance
measures using the WEDM process in the future.

Author Contributions: Conceptualization, M.T. and P.K.-O.; methodology, M.T. and P.K.-O.; software,
M.T.; validation, L.L. and Y.Z.; formal analysis, R.A. and R.M.; investigation, M.T. and A.E.; resources,
A.P.M.; writing—original draft preparation, M.T. and A.E.; project administration, M.T. and P.K.-O.;
funding acquisition, M.T. and P.K.-O. All authors have read and agreed to the published version of
the manuscript.
Funding: This research project was Supported By Open Fund (PLN2022-17) of the State Key Labora-
tory of Oil and Gas Reservoir Geology and Exploitation (Southwest Petroleum University).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Acknowledgments: This research project was partly supported by the program “Excellence initiative—
research university” from the A.G.H. University of Science and Technology, grant number IDUB: 4480.
Conflicts of Interest: The authors declare no conflict of interest.

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