Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are controllable variables for response characteristics, such as material removal (MRR) wear ratio (WWR). Box-Behnken applied design experiments collect observations from experiments. mathematical models each were developed using significant individual, interaction, quadratic terms by sequential sum square test. surfaces developed. It was revealed analysis that 52.92 % 24.63 Pulse-width, 12.81 pulse- interval 5.75 contributed MRR, while 14.89 9.75 62.20 5.44 WWR. pulse-width has more contribution on MRR due long period spark between work materials. also observed pulse-interval effect WWR ideal (high spark-pause-time) two consecutive high-temperature sparks in tool. been analysed scanning electron microscopy (SEM) photographs. desirability principles first obtain multi-objective solutions with combination parameters achieve optimal values both responses. predicted results validated data collected confirmation