Machining of Monel K-500 Materials

Abstract

This thesis uses WEDM to investigate the machining properties and difficulties of Monel K-500, a high-strength, corrosion-resistant nickel-copper alloy. Monel K-500 is widely utilized in sectors like chemical processing, aerospace, and marine because of its superior mechanical qualities and resilience to extreme conditions. Non-traditional procedures must be used, nevertheless, because of its propensity to work-harden and poor machinability when employing normal methods. In order to increase surface quality and material removal rates while reducing tool wear and dimensional inaccuracies, the research focuses on optimizing WEDM parameters, such as pulse length, wire tension, voltage, and current. Both AC and DC modes were used in the experiments to examine how they affected machining efficiency. Advanced 3D metrology systems (Alicona and MountainsLab) were used to measure important surface roughness metrics, including Sa, Sz, Ssk, and Sku. The findings suggest that careful selection of electrical and mechanical parameters significantly influences the machinability of Monel K-500, with DC mode generally offering smoother finishes under optimized conditions.