Multi-objective optimisation for wire EDM cutting: a comprehensive study for machining AL6061 aluminium alloy

<p dir="ltr">This paper investigates the optimal setup for machining aluminium alloy AL6061 materials by using Wire Electrical-Discharge Machining (WEDM). A robust design technique L27 orthogonal array with three distinct levels of process parameters and four machine input factors has been applied to optimise a multiple-objective-optimisation problem. Process parameters including feed rate, wire feed rate, discharge pulse time, and discharge stop time are addressed in experimental study to minimise surface roughness (SR) and wire wear ratio (WWR), and to maximise material removal rate (MRR). Response surface methodology (RSM) is used to formulate a regression model, which represents the relationship between factors and responses. Analysis of Variance (ANOVA) table are examined influences of each factor and interaction on objectives. Results indicate that the feed rate significantly influences on surface roughness, wire wear ratio, and material removal weight. While feed rate has a negative effect on surface roughness and wire wear ratio and has a positive impact on material removal weight. In addition, a set of optimal parameters for multi-objective optimisation of surface roughness and material removal weight is achieved by the genetic algorithm (GA) and compared to the actual experimental values to validate the proposed approach.</p>