A simple and reliable Taguchi approach for multi-objective optimization to identify optimal process parameters in nano-powder-mixed electrical discharge machining of INCONEL800 with copper electrode.

There is a need for heavy-duty machining equipment and tooling to minimize chatter due to work-hardening of the INCONEL materials ahead of cutting. Optimum EDM parameters are to be identified to produce quality products of INCONEL800. Modified Taguchi approach is adopted in the multi-objective optimization to identify the optimum peak current, pulse-on-time and pulse-off-time in the nano powder mixed EDM (n-PMEDM) of INCONEL800 with copper electrode for high material removal rate (MRR) and low surface roughness (SR). Empirical relations for MRR and SR are developed easily in terms of the EDM parameters without use of the MINITAB Release-16 software and validated with test results. Test results are found to be within the expected range. It also demonstrates the advantages of opting Taguchi approach to get complete information through few experiments.