Abstract

Lakki Rathore, Joji Thomas, Sanjay Kumar Vaidya, Anand Kumar Shriwas

ABSTRACT

In Wire Electrical Discharge Machining (WEDM), the selection of machining parameters plays a crucial role, particularly in rough cutting operations where the objective is to maximize material removal rate (MRR) while minimizing surface roughness (SR). Traditionally, parameter selection relies heavily on operator experience, which may not always yield optimal results. In the present study, four key control parameters pulse current, pulse-on time, pulse-off time, and servo feed were considered, each at three levels. Experiments were designed using an L27 orthogonal array based on the Taguchi method. The experimental results reveal that MRR increases with an increase in discharge current. Furthermore, Grey Relational Analysis (GRA) was employed to determine the optimal combination of machining parameters for achieving maximum MRR and minimum SR simultaneously. The study demonstrates the effectiveness of the integrated Taguchi–GRA approach in multi-objective optimization of WEDM process parameters.