Performance Prediction in Wire EDM Using Statistical and ML Techniques

Wire EDM plays a vital role in the precision machining of hard-to-cut materials, but its efficiency depends on the optimal selection of parameters. The influence of machining parameters on WEDM quality for Stainless Steel 202. This study integrates Taguchi’s L9 orthogonal design with machine learning (ML) to optimise and predict surface roughness (SR) outcomes. ANOVA revealed peak current as having a significant impact on machining quality, with a moderate non-significant effect from pulse on time; wire speed and pulse off time had minimal effect. Increased peak current and pulse on time result in higher discharge energy, which generates deeper craters on the workpiece surface, thereby leading to increased surface roughness. To boost predictive accuracy, three ML models—Random Forest (RF), Artificial Neural Network (ANN), and Support Vector Machine (SVM)— were evaluated by using k-fold cross-validation in addition to the conventional 80/20 train-test split. RF achieved the highest prediction accuracy (R² = 0.931), followed by ANN (R² = 0.918) and SVM (R² = 0.810). This approach minimises experimental efforts and enhances machining precision. The findings suggest that combining statistical tools with ML can streamline WEDM processes, improve surface quality, and reduce defects. Future work may focus on real-time control systems, hybrid optimisation, and deep learning models for further improvement