Application of multi-criteria decision making techniques for selection of wire-EDM process parameters

Wire Electric Discharge Machining (WEDM) is essential in precision machining, particularly for complex components. While previous research has investigated the optimisation of WEDM parameters for a variety of materials, little emphasis has been paid to aluminium metal matrix composites (AMMCs) reinforced with Al 2 O 3 . This work uses a unique method to optimise WEDM parameters—gap voltage (Vg), input current (IP), wire tension (WT), and dielectric pressure (Pd)—for machining Al6061 alloy reinforced with 6% Al 2 O 3 . Unlike previous research, which frequently focusses on single methodologies, this study compares three Multi-Criteria Decision-Making (MCDM) techniques: Grey Relational Analysis (GRA), Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), and Vise Kriterijumska Optimizacija Kompromisno Resenje (VIKOR). The findings provide novel insights into the optimal parameter combinations for achieving high machining rate (MR) and exceptional surface finish (Ra), bridging the parameter optimisation gap for AMMCs in WEDM applications.