Comparative Analysis of Linear and Circular Cut Geometry in WEDM Process of Inconel 825 Material Using Parametric Optimization

A non-traditional machining method based on thermal energy, wire electrical discharge machining (WEDM) can precisely machine conductive materials. In addition to the cost of slot cuts, process parameters are important since they vary depending on the material properties. Hence, it is necessary to employ an appropriate technique to regulate the process parameters and ensure the desired quality of the slot cut. This study involved using WEDM to machine Inconel-825. The experiment used a Taguchi [Formula: see text] orthogonal array (OA) for maximum cutting rate and minimum surface roughness (SR). Peak current (I), spark on time ([Formula: see text]), and spark off time ([Formula: see text]), which are WEDM process parameters, were considered. Analysis of variance (ANOVA) and ANOM identified the significant contribution of cutting rate and SR in terms of WEDM parameters. A MOORA-PCA analysis was conducted to determine the optimum parameter settings. The OA results showed that the best values were at I (5[Formula: see text]A), [Formula: see text] (50[Formula: see text]ms), and [Formula: see text] (8[Formula: see text]ms), with an assessment value of 0.9935 and 1.0558 for linear and circular cut, respectively. The best outcomes from the MOORA-PCA optimization procedures were compared to the experimental outcome, and an improvement of 22.5643% and 17.7085% in linear and circular cuts were found, respectively. Optimizing WEDM parametrically utilizing a commercially available Inconel 825 machining technique based on MOORA-PCA MCDM is feasible.