Multi-objectives optimization of WEDM parameters on machining of AISI 304 based on Taguchi method

Wire electrical discharge machining (WEDM) is utilized to cut sophisticated curves or shapes that would be challenging to cut using traditional techniques. The challenge lies in simultaneously optimizing multiple conflicting objectives, such as maximizing material removal rate (MRR) while minimizing surface roughness (SR) and kerf width, to achieve high-quality machining results. This study addresses this challenge by introducing a multi-objective optimization approach using the Taguchi method and the Design of Experiments (DOE) to optimize WEDM parameters. The WEDM model AQ327L cut a workpiece material from stainless steel AISI 304 using a 0.25-mm brass wire electrode diameter. The variable input parameters were a pulse on time (T_on), a pulse of time (T_off), and a peak current (I_P). The average of means analysis (ANOM), analysis of variance (ANOVA), and single-to-noise (S/N) ratio were used to determine the effect of WEDM parameters on the responses. The multi-objectives optimization introduced the ideal setting parameters were a combination of 11.33 μs T_on, 24 μs T_off, and 11 A I_P. ANOVA and ANOM demonstrated that the T_on followed by I_P are the most influential factors in the MRR and kerf width. In contrast, the T_on followed by the T_off are the most influential factors in SR. Finally, the findings demonstrated that the multi-objective optimization by the Taguchi approach could increase the quality of the WEDM process of AISI 304.