Wire EDM cutting of Inconel 718 nickel-based superalloy: kerf and MRR analysis

<jats:sec><jats:title content-type="abstract-subheading">Purpose</jats:title><jats:p>Inconel 718 (IN718) is a high-performance nickel-based superalloy with high oxidation-corrosion-temperature resistance, high strength (tensile, fatigue, creep and rupture), durability, toughness, hardness and dimensional stability, which is difficult to machine with traditional fabrication methods. To overcome these difficulties, wire electrical discharge machining (WEDM), one of the modern manufacturing methods, is used.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Design/methodology/approach</jats:title><jats:p>Main performance criteria in WEDM; material removal rate (MRR), cutting speed, surface roughness, cutting width (kerf) and wire wear rate. In this study, the effect of processing parameters on kerf and MRR because of processing IN718 in WEDM was investigated. Machining parameters, voltage, wire feed rate and dielectric fluid pressure were determined. Deionized water was used as a dielectric fluid and 0.3 mm brass wire was used as wire in the experiments. Gray Relational Analysis (GRA), which is one of the multi-criteria decision-making methods, has been applied for the optimization of the machining parameters in the cutting process with the WEDM. Analysis of variance (ANOVA) was used to determine the effect percentages of the cut-off parameters.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Findings</jats:title><jats:p>The parameter with the highest effect was determined as tension with a rate of 76.95% for kerf and 91.21% for MRR.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Originality/value</jats:title><jats:p>The novel approach uses Taguchi-based GRA optimization as a result of cutting IN718 with WEDM, reducing cost and time consumption.</jats:p></jats:sec>