Evaluating the performance of electrical discharge face grinding on super alloy monel 400

Conventional machining of super alloy Monel 400 is difficult due to its high strength, low heat conductivity, and gummy nature. In this work, the performance of the electrical discharge diamond face grinding (EDDFG) while processing supper alloy Monel 400 is assessed using the super abrasive diamond-coated grinding wheels of three different grit numbers. Preliminary experiments highlighted the superior performance of the EDDFG as compared to that of electrical discharge machining (EDM) and electrical discharge face grinding (EDFG); in terms of material removal rate (MRR), average surface roughness (Ra), and microscopic images of surfaces using scanning electron microscope (SEM). This work aimed to assess the influence of the diamond grit number (DG n ) of the grinding wheel along with other process parameters, viz. grinding wheel speed (GWS), peak current (I p ), and pulse-on-time (T on ) on Ra and MRR. The analysis of variance (ANOVA) confirmed that DG n and GWS significantly affect the response variables. Finally, the multi-objective genetic algorithm (GA) optimization approach was used to determine the optimal parametric settings of the EDDFG process.