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

Ultrasonic frequency vibration coupled micro-wire electrical discharge machining (UFV- μ 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- μ WEDM influencing machining parameters like ultrasonic frequency vibration (UFV), servo voltage ( V S ), time on ( T on ), cutting angle ( A C ), time off ( T off ), and current (I) on the Ni–Cr space alloy in terms of minimum surface undulation (Ra) with maximum material removal rate ( M RR ). 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 V S was the significant parameter impacting Ra (64.57%) and M RR (61.86%). The performance sequence of significant influencing parameters is V S > T off > A C > T on > I. According to desirability analysis (DA), optimum parameters for numerous solutions are T on = 8 μ s, V S = 5 0 V, T off = 1 4 μ s, I = 3 A, and A C = 3 0 ∘ . The optimum conditions lead to the highest M RR (5.72 mm3/min) and the lowest Ra (3.42 μ m). Scanning electron, 3D topography, and atomic force microscope images are used to analyze the machined surface. [ABSTRACT FROM AUTHOR]