<p>Metals and materials that are used in designing specific components in aerospace and industrial applications, such as injector nozzles, landing gear components, micro inserts, etc. have extreme hardness levels and complex geometries which require machining processes such as Wire Electrical Discharge Machining (WEDM). High Manganese Steel (HMS) is one such material recognized for its toughness, along with high impact strength and resistance to wear, which makes it difficult to machine according to the application. In order to select appropriate parameters for the WEDM process of HMS material, this research uses Central Composite Design (CCD) and Firefly Algorithm (FA) optimization techniques to examine how different machining parameters affect the outcomes of the process. The research aims to improve the factors for improved efficiency through the assessment of three different factors, including Pulse on time <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\left({\text{t}}_{{\text{P}}_{\text{on}}}\right)\)</EquationSource> </InlineEquation>, Pulse off time <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\left({\text{t}}_{{\text{P}}_{\text{off}}}\right)\)</EquationSource> </InlineEquation> and Servo Voltage <InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(\left(\text{S}\text{V}\right)\)</EquationSource> </InlineEquation>, while using brass material wire as a cutting tool. Material Removal Rate (MRR) and Cutting Speed (CS) are selected as responses for optimization. The analysis conducted depicts the best machining results for single objective optimization with MRR as 117.64 mg/min at <InlineEquation ID="IEq4"> <EquationSource Format="TEX">\({\text{t}}_{{\text{P}}_{\text{on}}}= 12 \upmu \text{s}\text{e}\text{c}, {\text{t}}_{{\text{P}}_{\text{off}}}= 20 \upmu \text{s}\text{e}\text{c}\)</EquationSource> </InlineEquation> and SV = 40 V. While single objective optimization of CS reveals 3.6948 mm/min, at <InlineEquation ID="IEq5"> <EquationSource Format="TEX">\({\text{t}}_{{\text{P}}_{\text{on}}}= 12 \upmu \text{s}\text{e}\text{c}, {\text{t}}_{{\text{P}}_{\text{off}}}= 60 \upmu \text{s}\text{e}\text{c},\)</EquationSource> </InlineEquation> and SV = 60 V. Multi-objective FA (MO_FA) with weight consideration for MRR and CS as 50%-50%, maximum MRR achieved is 124.483 mg/min, and maximum CS is 4.7453 mm/min simultaneously.</p>

Parametric Optimization of WEDM by Firefly Algorithm for High Manganese Steel Material

期刊论文
发表日期：

2026年5月25日

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Sachindra Kumar,
Om ji Shukla,
Sonu Rajak

摘要

Metals and materials that are used in designing specific components in aerospace and industrial applications, such as injector nozzles, landing gear components, micro inserts, etc. have extreme hardness levels and complex geometries which require machining processes such as Wire Electrical Discharge Machining (WEDM). High Manganese Steel (HMS) is one such material recognized for its toughness, along with high impact strength and resistance to wear, which makes it difficult to machine according to the application. In order to select appropriate parameters for the WEDM process of HMS material, this research uses Central Composite Design (CCD) and Firefly Algorithm (FA) optimization techniques to examine how different machining parameters affect the outcomes of the process. The research aims to improve the factors for improved efficiency through the assessment of three different factors, including Pulse on time \(\left({\text{t}}_{{\text{P}}_{\text{on}}}\right)\) , Pulse off time \(\left({\text{t}}_{{\text{P}}_{\text{off}}}\right)\) and Servo Voltage \(\left(\text{S}\text{V}\right)\) , while using brass material wire as a cutting tool. Material Removal Rate (MRR) and Cutting Speed (CS) are selected as responses for optimization. The analysis conducted depicts the best machining results for single objective optimization with MRR as 117.64 mg/min at \({\text{t}}_{{\text{P}}_{\text{on}}}= 12 \upmu \text{s}\text{e}\text{c}, {\text{t}}_{{\text{P}}_{\text{off}}}= 20 \upmu \text{s}\text{e}\text{c}\) and SV = 40 V. While single objective optimization of CS reveals 3.6948 mm/min, at \({\text{t}}_{{\text{P}}_{\text{on}}}= 12 \upmu \text{s}\text{e}\text{c}, {\text{t}}_{{\text{P}}_{\text{off}}}= 60 \upmu \text{s}\text{e}\text{c},\) and SV = 60 V. Multi-objective FA (MO_FA) with weight consideration for MRR and CS as 50%-50%, maximum MRR achieved is 124.483 mg/min, and maximum CS is 4.7453 mm/min simultaneously.