Advanced Process Modeling and Optimization of Wire Electrical Discharge Machining for Austenitic Stainless Steel Using Statistical and Desirability Frameworks

This study investigates the optimization of Wire EDM parameters for X5CrNi18-10 austenitic stainless
steel, focusing on maximizing cutting rate (CR) while minimizing surface roughness (Ra) and cut width
(CW). A response surface methodology based on a Box–Behnken Design was employed to conduct
experiments and develop predictive models for the responses as a function of voltage (V), pulse interval (I),
pulse duration (D), and cutting feed (F). ANOVA revealed that pulse duration and cutting feed significantly
influenced all three responses. Pulse interval also showed significant effects on CR and CW. Quadratic
regression models were developed, demonstrating a good fit for CR and CW, while the Ra model indicated a
significant lack of fit. Multi-criteria optimization using the desirability framework identified an optimal
parameter set (V = 65 volts, I = 45.49 ls, D = 103.57 ls, F = 8.94 m/min) achieving a high combined
desirability of 0.903. A validation experiment at these settings yielded a CR of 41.73 mm3/min, an Ra of
1.03 lm, and a CW of 0.315 mm, showing good agreement with predictions for CR and CW but a larger
deviation for Ra. Surface morphology analysis using SEM revealed rougher surfaces at maximum CR
conditions compared to the finer texture at optimized conditions. Surface roughness profiles confirmed a
significant reduction in Ra at the optimized settings. Video measuring instrument images showed a narrower and more uniform cut at optimized conditions compared to the wider kerf at maximum CW conditions. The optimized parameters offer a balanced performance, and the developed models can be utilized
for predicting and controlling the Wire EDM process for this material.