Multi-objective process optimization of wire electrical discharge machining based on response surface methodology

Determining the optimal cutting parameters has always been a critical matter to achieve high performance in different types of machining. In this study the behavior of four major control parameters includes pulse on time (Ton), pulse off time (Toff), peak current (IP), and servo voltage base on design of experiment method during wire electrical discharge machining of titanium alloy (Ti6Al4 V) experimentally studied. A zinc-coated brass wire of 0.25 mm diameter was used as a tool electrode to cut the specimen. Analysis of variance (ANOVA) technique was used to find out the parameters affecting the surface roughness, sparking gap, wire lag, wire wear ratio, and white layer thickness. Assumptions of ANOVA were discussed and carefully examined. This work has been established as a second-order mathematical model based on the response surface methodology. The residual analysis and confirmation runs indicate that the proposed model could adequately describe the performance of the factors those are being investigated. The results are particularly useful for scientists and engineers to determine which subset of the process variable has the maximum influence on the process performance.