Analysis and Optimization of Process Parameters in Wire Electrical Discharge Machining Based on RSM: A Case Study

Abstract

In this book chapter a review and critical analysis on current research trends in wire electrical discharge machining (WEDM) and relation between different process parameters including pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap, wire lag and wire wear ration (WWR) and surface integrity factors was investigated. On the basis of critical evaluation of the available literature following conclusions are summarized. In addition, different modeling and optimization methods used in WEDM were discussed and a case study based on response surface method (RSM) including design of experiment (DoE) carried out to find optimal process parameters effect on surface roughness was conducted. In the final part of the present study was presented some recommendations about the trends for future WEDM researches.