Form variation management of products in Inconel 718 obtained through EDM process with circular shape brass electrodes

The main aim of this experimental work is to analyse the influence of circular shape brass electrodes and process parameters on material removal rate, tool wear and part form deviations in the EDM process of Inconel 718 nickel-based alloy in the die-sinking EDM process. Three major process parameters, namely peak current, pulse on time and pulse off time, were selected to perform experiments using 3 mm diameter circular shape brass electrodes. The influence of the selected process parameters was analysed using hybrid Taguchi and multi-criteria decision grey relational analysis methods on workpiece form deviations, electrode wear rate and material removal rate. The dominance of each process parameter was analysed with an artificial intelligence-based ANFIS model and the developed model showed a minimum mean percentage error. Finally, the form deviations on the holes of two plates obtained by the EDM process were transferred to an assembled product to verify its assembling.