Review of Process Parameters of WEDM through Response Surface Methodology

Wire Electrical Discharge Machining (WEDM) is a widely used non-conventional machining process that utilizes electric sparks to remove material from conductive workpieces. The efficiency and precision of the WEDM process are influenced by various process parameters, such as pulse-on time, pulse-off time, peak current, and wire tension. In this study, the process parameters of WEDM were investigated using the Response Surface Methodology (RSM) to optimize the performance of the machining process. The objective of this research was to determine the optimal levels of process parameters that would yield improved machining performance in terms of material removal rate (MRR) and surface roughness (Ra). A full factorial design was employed to determine the significant parameters and their interactions, followed by the RSM to develop mathematical models and perform optimization. The optimization process was carried out using the desirability function approach to find the combination of process parameters that would maximize MRR and minimize Ra simultaneously. The optimized parameters were validated through confirmation experiments, and the results were compared with the predicted values.