Analysis of the sensitivity of the parameters affecting the rate of removal, surface roughness and width in the wire electrical discharge machining

One of the most attractive modern machining methods is electrical discharge machining, which was introduced in the late 1960s. Electric discharge machining with wires has a number of uses, including high accuracy machining of all conductive materials such as metals, metal alloys, graphite, and ceramics, as well as aerospace, automotive, and other industries. In order to increase the rate and reduce surface roughness and gap width, optimal cutting parameters play a crucial role in selecting output parameters. In this study, input parameters (discharge, pulse duration, pulse frequency, wire speed, wire tension, and dielectric current velocity) were compared to output variables (cutting rate, surface filter, and width). The sensitivity analysis shows that pulse duration parameters, wire speed, and discharge flow are most effective parameters for cutting rate, and pulse duration parameters, dielectric rate, and discharge flow are most effective parameters for surface roughness, as well as pulse duration, wire speed, and discharge current for gap width. Pulse duration with 72%, wire speed with 14%, and discharge current with 10% has the greatest impact on the chip removal rate.