Prediction of Wire-EDM Machining Parameters for Optimum of Surface Finish and MRR in an Aluminum Alloy 7075-T6

Wire-cut EDM is a process that works by continuously feeding a wire electrode under tension on a vertical axis. A discharge voltage is applied through the wire, crosses via a dielectric liquid, and strikes the grounded work-piece. The work-piece is moved in an X-Y plane to trace a cut pattern through the material. The process is applicable to cut complex and elaborate shapes of workings in all conductive, hard and thicker materials. An appropriate modeling can advance the machining presentation and the product exactness. Surface Response Methodology (RSM) coupled with grey relation analysis method has been proposed to predict the performance characteristics namely the surface roughness and material removal rate of WEDM on the alloy AL7075-T6 work-piece material. Selected input parameters such as pulse on time, pulse off time, wire feed, wire tension and dielectric pressure. ANOVA is applied to determine significance of the input parameters for optimizing the process.