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Recently, DC53 die steel was introduced to the die and mold industry because of its excellent characteristics i.e., very good machinability and better engineering properties. DC53 demonstrates a strong capability to retain a near-net shape profile of the die, which is a very challenging process with materials. To produce complex and accurate die features, the use of the wire electric discharge machining (WEDM) process takes the lead in the manufacturing industry. However, the challenge is to understand the physical science of the process to improve surface features and service properties. In this study, a detailed yet systematic evaluation of process parameters investigation is made on the influence of a wire feed, pulse on duration, open voltage, and servo voltage on the productivity (material removal rate) and material quality (surface roughness, recast layer thickness, kerf width) against the requirements of mechanical-tooling industry. Based on parametric exploration, wire feed was found the most influential parameter on kerf width: KW (45.64%), pulse on time on surface roughness: SR (84.83%), open voltage on material removal rate: MRR (49.07%) and recast layer thickness: RLT (52.06%). Also, the optimized process parameters resulted in 1.710 µm SR, 10.367 mm3/min MRR, 0.327 mm KW, and 10.443 µm RLT. Moreover, the evolution of surface features and process complexities are thoroughly discussed based on the involved physical science. The recast layer, often considered as a process limitation, was explored with the aim of minimizing the layers’ depth, as well as the recast layer and heat-affected zone. The research provides regression models based on thorough investigation to support machinists for achieving required features.

Stainless steel (SS 304) is commonly employed in industrial applications due to its considerable corrosion resistance, thermal resistance, and ductility. Most of its intended applications require the formation of complex profiles, which justify the use of wire electrical discharge machining (WEDM). However, its high thermal resistance imposes a limitation on acquiring adequate surface topography because of the high surface tension of the melt pool, which leads to the formation of spherical modules, ultimately, this compromises the surface quality. Furthermore, the stochastic nature of the process makes it difficult to optimize its performance, especially if more than one conflicting response is involved, such as high cutting speed with low surface roughness and kerf width. Therefore, this study aimed to comprehensively investigate the interaction of SS 304 and WEDM, with a prior focus on simultaneously optimizing all the conflicting responses using the Taguchi-based grey relational approach. Analysis of variance (ANOVA) revealed that the current was the most significant parameter for cutting speed and kerf, whereas roughness, voltage (45%), drum speed (25.8%), and nozzle offset distance (~21%) were major contributing factors. SEM micrographs showed that optimal settings not only ensured simultaneous optimization of the conflicting responses but also reduced the number and size of spherical modules.

This study researched the effects of machining parameters on surface roughness and material removal rate in the wire electrical discharge cutting of high-density Al/B4C metal matrix composites produced via the hot pressing method. Wire tension, reinforcement percentage, wire speed, pulse-on time and pulse-off time were set as the control factors. The Taguchi L18 (21 × 34) orthogonal array was used in the experiment design and determination of the optimum control factors. Variance analysis was applied to determine the effects of the control factors on the surface roughness and material removal rate. The results showed the most effective parameters to be pulse-on time (30.22%) for surface roughness and wire speed (83.20%) for material removal rate, and the optimum levels of the control factors to be A2B1C2D1E1 and A2B2C3D2E2, respectively. Predictive equations were then developed by applying linear regression analysis, and the adjusted correlation coefficients were calculated as 0.61 for surface roughness and 0.785 for material removal rate.

Present study has been made to optimize the process parameters during machining of SiCp/6061 Al metal matrix composite (MMC) by wire electrical discharge machining (WEDM) using response surface methodology (RSM). Four input process parameters of WEDM (namely servo voltage (V), pulse-on time (TON), pulse-off time (TOFF) and wire feed rate (WF)) were chosen as variables to study the process performance in terms of cutting width (kerf). The analysis of variance (ANOVA) was carried out to study the effect of process parameters on process performance. In addition mathematical models have also been developed for response parameter. Properties of the machined surface have been examined by the scanning electron microscopic (SEM).

The micro-wire electric discharge machining (micro-WEDM) has emerged as the popular micromachining processes for fabrication of micro-features. However, the low machining rate and poor surface finish are restricting wide applications of this process. Therefore, in this study, an attempt was made to improve machining rate of micro-WEDM with low-frequency workpiece vibration assistance. The gap voltage, capacitance, feed rate and vibrational frequency were chosen as control factors, whereas, the material removal rate (MRR) and kerf width were selected as performance measures while fabricating microchannels in Inconel 718. It was observed that in micro-WEDM, the capacitance is the most significant factor affecting both MRR and kerf width. It was witnessed that the low-frequency workpiece vibration improves the performance of micro-WEDM by improving the MRR due to enhanced flushing conditions and reduced electrode-workpiece adhesion.