Study on process characteristics of wire electrical discharge machining for YG8 tungsten carbide based on response surface methodology

Abstract YG8 Tungsten Carbide, a high-density, difficult-to-machine composite, is extensively utilized in military and aerospace applications. To enhance its Wire Electrical Discharge Machining (WEDM) processing efficacy, this study employed Response Surface Methodology (RSM) with a Box-Behnken design. This article investigated four key parameters—Pulse Duration (Ton), Pulse Gap (Toff), Average Current (Ip), and Wire Speed (WS)—regarding their effects on Material Removal Rate (MRR) and Surface Roughness (Ra), aiming to identify optimal processing conditions. A four-factor, three-level experimental design established quadratic regression models. Main and interaction effect analyses were performed to optimize parameter combinations for minimized Ra and maximized MRR. Results indicate the optimal electrical parameter set for simultaneous MRR maximization and Ra minimization is: Ton = 28 μs, Toff = 3 μs, IP = 9 A, WS = Gear 1. This configuration yielded workpieces with high cutting efficiency (MRR = 41.38 mm 2 min −1 ) and superior surface quality (Ra = 2.431 μm).