Modelling and optimization of process parameters of wire electrical discharge machining.

Abstract

The optimum selection of process parameters is essential for advanced machining processes as these processes incur high initial investment, tooling cost, operating cost, and maintenance cost. Wire electrical discharge machining (WEDM) is a widely accepted advanced material removal process used to manufacture components with intricate shapes and profiles. The present work highlights the development of mathematical models using response surface modelling (RSM) for correlating the inter-relationships of various WEDM parameters such as pulse-on time, pulse-off time, peak current, and servo feed setting on the machining speed and surface roughness. A recently developed advanced optimization technique, known as artificial bee colony (ABC), is then applied to find the optimal combination of process parameters with an objective of achieving maximum machining speed for a desired value of surface finish.