Parameter optimization and surface integrity aspects in MWCNT-based nano-PMEDM process of Inconel 718

This study examines the effects of Inconel 718’s Nano PMEDM process parameters on Material Removal Rate (MRR), Tool Wear Rate (TWR), Surface Roughness (SR), and the integrity of surface and subsurface layers. It also examines the concentration of MWCNT nanoparticles in distilled water as a dielectric medium. Peak Current, Pulse on Time, and Powder Concentration were input variables in 20 experimental runs utilizing the Central Composite Design (CCD) of Design of Expert (DOE). To create and evaluate empirical models for MRR, TWR, and SR, response surface methodology (RSM) and ANOVA were used. According to the results of the improved RSM, the best responses for MRR, TWR, and SR are 0.012 g/min, 0.001 g/min, and 5.098 µm, respectively. These were accomplished by cutting parameters of 1.5 g/L for powder concentration, 307.967 s for pulse on time, and 19.925 Amps for peak current. GA optimization produced slightly different optimal values for MRR, TWR, and SR: 0.012 g/min, 0.003 g/min, and 5.229 µm, respectively. 20.178 Amps for Peak Current, 398.753 seconds for Pulse on Time, and 3.66 g/L for Powder Concentration were the suggested ideal cutting conditions for GA optimization. In the validation tests, both the GA-predicted outcomes and RSM-optimized values closely matched the experimental results.