Analysis of multivariate optimization of WEDM through response surface methodology and grey relational analysis for C632 bronze parameters of surface roughness and material removal rate

Wire electric-discharge machining (WEDM) guarantees high levels of fidelity and precision, making it an especially valuable method for working with intricate designs in conductive materials that are challenging to manufacture. The present work aims the improvement of the process parameters during wire electro-spark machining for C632 Bronze. The experimental runs were conducted according to the Box-Behnken design (BBD) based on response surface methodology. The capability of electro-spark machining was tested by a number of processing parameters. The machining characteristics were studied for a highly demanded material, C632 Bronze, that is, used in light-duty gears and sprockets, impellers, wear strips, plates, automotive fittings, and washers. Both ANOVA and Grey Relational Analysis (GRA) were used to investigate the significance of the process variables. The new process factors, obtained with the use of GRA, have resulted in better results reasonably close to an acceptable error range. The surface topography of the treated C632 Bronze was also characterized using scanning electron microscopy.