Optimization and Regression Modeling of Wire Electrical Discharge Machining for Cupronickel Material

Wire Electrical Discharge Machining (WEDM) is a highly accurate machining method that is well-known for its capacity to create complex forms in conductive materials with exceptional precision. Cupronickel, a hard material consisting of copper, nickel, and additional components, is widely employed in marine, automotive, and electrical engineering fields because of its exceptional ability to resist corrosion and conduct heat. The objective of this study is to optimize the parameters of Wire Electrical Discharge Machining (WEDM) for Cupronickel material and create regression models to accurately forecast the performance of the machining process. An investigation was carried out to examine the impact of important parameters in wire electrical discharge machining (WEDM), namely pulse-on time, pulse-off time, applied current on key performance indicators such as material removal rate (MRR), surface roughness (Ra). The methodology of design of experiments (DOE) enabled a systematic exploration of parameters. Regression models were created using statistical methods to determine the connections between process parameters and performance indicators. These models offer a prognostic tool for optimizing WEDM parameters and attaining desired machining results. The results exhibited the efficacy of the regression models in accurately forecasting the machining performance for Cupronickel material. The models provide valuable insights into the most effective parameter configurations for maximizing machining efficiency and surface quality. Manufacturers can improve machining productivity and quality in precision engineering applications by utilizing regression models, thereby facilitating the wider implementation of WEDM technology.