Use of RSM desirability approach to optimize WEDM of mild steel

Abstract Wire Electrical Discharge Machining (WEDM) is a non-traditional material removal process commonly used for precision machining of hard materials such as super alloys, ceramics, carbide, and composite materials. Optimization of process parameters is critical for improving machining efficiency and achieving the desired surface quality. Response Surface Methodology (RSM) systematically optimizes process parameters and investigates their impact on machining performance. WEDM control parameters such as pulse ON Time (T ON ) (50–60 μs), pulse OFF Time (T OFF ) (25–34 μs), gap voltage (V G ) (25–250 V), peak current (I P ) (1–6 A), and dielectric flow rate (D f ) (1–3 LPM) are optimized to reduce surface roughness (SR) and taper angle (TA) while increasing material removal rate (MRR) during the machining of Mild Steel. The optimal parameters are T ON as 53 μs, T OFF as 28 μs, I P as 2.65 A, V G as 185 V, and D f as 1.5 LPM. The experimental findings are presented to demonstrate the usefulness of the proposed strategy in optimizing WEDM control parameters. The validation test was conducted under optimal conditions and the results were reported. The manufacturing industries can use RSM optimization in the manufacturing domain.