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Sensitivity Analysis of Input Parameters in Wire Electric Discharge Machining Using Response Surface Methodology

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Abstract:

Wire Electrical Discharge Machining (WEDM) is a non-traditional machining method for fabricating hard and conductive materials. This study investigates the influence of four key process parameters such as pulse on-time, pulse off-time, wire feed rate, and current on machining performance using stainless steel 316. The effect of these process parameters is studied in terms of volumetric material removal rate (VMRR), surface roughness (Ra), and side gap. Experiments were conducted using a CNC WEDM setup, and the results were analyzed using Response Surface Methodology (RSM) via Minitab 17 to develop regression models. The results show that wire feed and the current predominantly influence VMRR, pulse on-time has the strongest effect on Ra, while pulse off-time and the current are most significant for controlling side gap. The study offers a data-driven reference for optimizing WEDM process while contributing to improved machining performance, energy efficiency, and surface integrity to machine hard materials.

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Periodical:

Key Engineering Materials (Volume 1058)

Pages:

153-161

DOI:

https://doi.org/10.4028/p-okPz4o

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Online since:

June 2026

Authors:

Osama Ali*, Atif Niaz, Dong Won Jung

Keywords:

Minitab, Response Surface Methodology, Surface Roughness, Volumetric Material Removal Rate, Wire Electrical Discharge Machining

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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