Investigation of Wire-Cut EDM parameters for machining 2304 duplex stainless steel: effects on material removal rate, surface roughness, and tool wear

This study investigates the optimization of Wire-Cut Electrical Discharge Machining (WEDM) for 2304 duplex stainless steel, a material valued for its superior mechanical properties and corrosion resistance in challenging environments such as oil and gas, marine, and chemical industries. The study aims to evaluate how WEDM parameters-pulse duration, peak current, and wire speed-affect MRR, surface roughness (Ra), and tool wear. Using a Taguchi-based design of experiments (DoE) method, machining trials were conducted by varying these parameters. Results showed that Material Removal Rate (MRR) and surface roughness increased with longer pulse durations and higher peak currents, demonstrating a direct relationship. MRR peaked at 8.8 mm3/s at 300 mu s pulse duration and 30 A peak current, while surface roughness increased to 2.1 mu m under the same conditions. ANOVA analysis confirmed that pulse duration had the most significant effect on MRR and surface roughness, accounting for 58% and 54% of the variation, respectively. Tool wear, which increased with higher discharge energies, was mainly influenced by peak current, contributing to 45% of the observed variance. This study concludes that optimizing WEDM parameters can enhance machining performance while balancing MRR, surface finish, and tool wear trade-offs.