Multi-objective optimization of SKD61 steel WEDM to improve cutting velocity and reduce surface roughness

Abstract

This studywork systematically investigated the effects of
technological parameters on the technological responses, including
the cutting velocity (CV) and surface roughness (SR) in the WEDM
of SKD61 material. Technological parameters consist of current I,
pulse on time Ton, pulse of time Toff, and wire speed S. A WEDM
machine was adopted in conjunction with the Box-Behnken matrix
to conduct experimental trails. The nonlinear relationships between
process parameters and responses were developed using response
surface method (RSM). Subsequently, an optimization technique
entitled multiple objective particle swarm optimization (MOPSO)
was used to solve the trade-off analysis between responses
considered and find the optimal parameters. The measured
improvements using optimal parameters of the CV and SR are
approximately 12.32 % and 53.08 % in comparison with initial
settings. A hybrid approach comprising RSM and MOPSO can be
considered as an effective method for parameter optimization and
observation of reliable values in WEDM processes.