Optimizing WEDM Parameters for Aluminum Metal Matrix Composites Using Hybrid PSO-TOPSIS Approach

This study investigates the influence of processing conditions during wire electro-discharge machining (WEDM) of aluminum matrix composites (AMCs) using advanced optimization techniques, namely particle swarm optimization (PSO) and the technique for order preference by similarity to ideal solution (TOPSIS). Key WEDM parameters– pulse-on time, pulse-off time, wire feed rate and reinforcement percentage — were analyzed for their effects on cutting rate (CR), kerf width (KW) and surface roughness (SR). Microstructural examination confirmed the absence of intermetallic compounds around rice husk ash particles, and the cast AMCs exhibited no defects such as porosity or inclusions. Optimization using PSO and TOPSIS yielded highly consistent results, with minimal deviations (3.1–3.5%) between the two methods. The optimal parameters were determined as pulse-on time: 14 [Formula: see text]s, pulse-off time: 52[Formula: see text]s, wire feed rate: 6 m/min, and reinforcement: 4 wt.%. These settings significantly enhanced machining performance, demonstrating the robustness of the proposed approach. The study provides critical insights into optimizing WEDM for AMCs, ensuring improved efficiency and precision in industrial applications.