Optimization of Wire Electrical Discharge Machining Parameters for SAE 1010 Material Using TOPSIS Method

Wire Electrical Discharge Machining (WEDM) is a highly adaptable machining process that is extensively employed across various engineering industries to achieve precise machining of conductive materials. SAE 1010, a steel with low carbon content, is widely used in automotive, aerospace, and machinery components because it can be welded easily and shaped effectively. The objective of this study is to optimize the parameters of Wire Electrical Discharge Machining (WEDM) for SAE 1010 material by employing the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. An empirical study was carried out to examine the impact of crucial machining variables, such as pulse-on time, pulse-off time, applied current on performance metrics of machining, such as material removal rate (MRR), surface roughness (Ra). The utilization of the design of experiments (DOE) methodology enabled the methodical investigation of the parameter space. Taguchi based TOPSIS provides a comprehensive approach to parameter optimization in WEDM by taking into account both the closeness to the ideal solution and the distance from the negative ideal solution. The results showcased the efficacy of the TOPSIS technique in identifying the optimal parameter combinations for improving the efficiency of machining and the quality of the surface of SAE 1010 components. The implemented optimization methodology offers a methodical structure for enhancing the efficiency of WEDM procedures, specifically in demanding materials such as SAE 1010 steel. This study enhances the comprehension of Wire Electrical Discharge Machining (WEDM) of SAE 1010 material and provides valuable guidance on optimizing parameters for various machining processes. Manufacturers can enhance efficiency and quality in the machining of intricate components made from materials like SAE 1010 by utilizing the TOPSIS method.