Comparative study of statistical and soft computing approaches for forecasting material removal rate and temperature in the EDM process of Inconel 718
Year: 2025
Type: article
Abstract: Machining challenging materials such as Inconel 718 is typically accomplished through the use of electro discharge machining (EDM). This work presents a comprehensive comparative analysis of statistical and soft computing approaches aimed at forecasting temperature distribution and material removal rate (MRR) in the electrical discharge machining of Inconel 718. Utilizing Gaussian heat flow distribution alongside temperature-dependent material properties, a three-dimensional transient thermal model was developed in ANSYS Workbench. The model exhibited strong consistency when validated against experimental results and existing literature. The effects of pulse-on time, discharge current, and heat transfer fraction (F = 0.2–0.4) on thermal behavior and crater development were thoroughly examined, revealing significant findings. The findings indicate that Inconel 718 exhibits distinct thermal gradients due to its low thermal conductivity, with increased pulse-on duration and current leading to higher material removal rates and peak temperatures. Responses for EDM were projected utilizing various regression analyses, including ANOVA, alongside an artificial neural network model. The impressive predicted accuracy of the ANN model demonstrates its effectiveness for complex nonlinear modeling tasks. The work establishes a validated computational and data-driven framework aimed at optimizing EDM parameters, with significant implications for enhancing machining productivity, reducing tool wear, and improving surface quality in aerospace and tooling applications.
Source: Discover Mechanical Engineering
Authors: Apurva Kulkarni, Ganesh Dongre
Institution: Vishwakarma Institute of Technology
Language: English
Subfield: Electrical and Electronic Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,390
OpenAlex ID: W4416718405