Investigation and optimization of process parameters in the electrical discharge machining process for Inconel 660 using response surface methodology

Based on its exceptional mechanical and thermal qualities, Inconel 660 is a high-performance superalloy that is frequently used in marine and aerospace engineering. However, attaining the ideal material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) is severely hampered by its low machinability. This study uses Response Surface Methodology (RSM) based on the Box-Behnken Design (BBD) to examine the impacts of different process parameters in Electrical Discharge Machining (EDM) of Inconel 660. Statistical models were created to forecast performance results, and experimental trials were carried out to optimize machining parameters. The results show that whereas pulse-off time primarily affects SR, current and pulse-on time have a considerable impact on MRR and TWR. The adjusted parameters offer improved machining performance by decreasing electrode wear and enhancing surface morphology. These insights allow Inconel 660 and related superalloys to be machined more effectively.