Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

Charles Sarala Rubi; Jayavelu Udaya Prakash; Sunder Jebarose Juliyana; Robert Čep; Sachin Salunkhe; Karel Kouril; Sharad Ramdas Gawade

doi:10.3389/fmech.2024.1322605

Sarala Rubi, Charles;Udaya Prakash, Jayavelu;Jebarose Juliyana, Sunder;Čep, Robert;Salunkhe, Sachin;Kouril, Karel;Ramdas Gawade, Sharad

2024-01-23 00:00:00

TYPE Review PUBLISHED 23 January 2024 DOI 10.3389/fmech.2024.1322605 Comprehensive review on wire electrical discharge machining: a OPEN ACCESS EDITED BY Jianlin Liu, non-traditional material China University of Petroleum (East China), China removal process REVIEWED BY Angelos P. Markopoulos, National Technical University of Athens, Greece 1 2 Charles Sarala Rubi , Jayavelu Udaya Prakash , Milan Bukvic, 2 3 4,5 University of Kragujevac, Serbia Sunder Jebarose Juliyana , Robert Čep , Sachin Salunkhe *, 6 7 *CORRESPONDENCE Karel Kouril and Sharad Ramdas Gawade Sachin Salunkhe, [email protected] Department of Physics, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, India, Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D RECEIVED 16 October 2023 Institute of Science and Technology, Chennai, India, Department of Machining, Assembly and ACCEPTED 09 January 2024 Engineering Metrology, Faculty of Mechanical Engineering, VSB—Technical University of Ostrava, PUBLISHED 23 January 2024 Ostrava, Czechia, Department of Biosciences, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai, India, Department of Mechanical Engineering, Gazi CITATION University, Ankara, Turkey, Faculty of Mechanical Engineering, Institute of Manufacturing Technology, Sarala Rubi C, Prakash JU, Juliyana SJ, Čep R, Brno University of Technology, Brno, Czechia, Sharadchandra Pawar College of Engineering and Salunkhe S, Kouril K and Ramdas Gawade S (2024), Comprehensive review on wire Technology, Baramati, India electrical discharge machining: a non- traditional material removal process. Front. Mech. Eng 10:1322605. doi: 10.3389/fmech.2024.1322605 A highly advanced thermo-electric machining technique called wire electrical COPYRIGHT discharge machining (WEDM) can effectively produce parts with varying hardness © 2024 Sarala Rubi, Prakash, Juliyana, Čep, Salunkhe, Kouril and Ramdas Gawade. This is an or complicated designs that have sharp edges and are very difﬁcult to machine open-access article distributed under the terms using standard machining procedures. This useful technology for the WEDM of the Creative Commons Attribution License operation depends on the typical EDM sparking phenomena and makes use of the (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original commonly used non-contact material removal approach. Since its inception, author(s) and the copyright owner(s) are WEDM has developed from a simple approach for creating tools and grown to an credited and that the original publication in this outstanding option for creating micro-scale components having the greatest journal is cited, in accordance with accepted academic practice. No use, distribution or degree of dimensional precision and surface ﬁnish characteristics. The WEDM reproduction is permitted which does not method has endured over time as an efﬁcient and affordable machining comply with these terms. alternative that can meet the stringent operating speciﬁcations enforced by rapid manufacturing cycles and increasing expense demands. The possibility of wire damage and bent, nevertheless, has severely hindered the process’ maximum potential and decreased the precision as well as effectiveness of the WEDM process. The article examines the wide range of investigations that have been done; from the WEDM through the EDM process’ spin-offs. It describes WEDM investigation that required variables optimization and an assessment of the many inﬂuences on machining efﬁciency and accuracy. Additionally, the research emphasizes adaptive monitoring and control of the process while examining the viability of multiple approaches to control for achieving the ideal machining parameters. Numerous industrial WEDM applications are described with the advancement of hybrid machining Abbreviations: ANN, Artiﬁcial Neural Network; ANOVA, Analysis of Variance; CCRD, central composite rotatable design; CNC, Computer Numerical Control; CS, Cutting Speed; DoE, Design of Experiments; F, Feed rate; GA, Genetic Algorithm; GC, Gap Current; GRA, Grey Relational Analysis; GV, Gap Voltage; I Peak current; K , Kerf Width; MP, Melting Point; MRR, Material removal rate; P, Pressure of di-electric ﬂuid; RSM, Response Surface Methodology; SF, Servo Feed Rate; SR, Surface Roughness; SV, Servo voltage; T , Pulse off time; T , Pulse on time; TS, Tensile Strength; TWR, Tool Wear Rate; V, Voltage; W, off on Tungsten; WEDM, Wire Electrical Discharge Machining; WF, Wire Feed; WT, Wire Tension. Frontiers in Mechanical Engineering 01 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 techniques. The paper’s conclusion examines these advancements and identiﬁes potential directions for subsequent WEDM research. The investigation on WEDM of metal matrix composites (MMCs) is also reviewed; along with the impacts of various cutting variables like wire feed rate (F), voltage (V), wire tension (WT), and dielectric ﬂow rate on cutting processes outcomes like material removal rate (MRR), kerf width (K ) and surface roughness (SR). In the present article, future directions for WEDM research were also suggested. KEYWORDS wire EDM, composite materials, optimization, DOE, adaptive control 1 Introduction methods, unconventional machining techniques are typically linked to low productivity and high effective consumption of In the mid of the 1960s, WEDM was ﬁrst introduced to the energy (Madic and Radovanovic, 2015; La Monaca et al., 2021). industrial sector. The process was created as a result of research into However, unconventional machining can result in the creation of techniques for replacing the machined electrode used in EDM. In accurate characteristics with a high precision and SR when the order to autonomously regulate the physical form of the component proper machining conditions are strictly followed (Farooq et al., that would be machined using the WEDM procedure, D.H. Dulebohn 2020). Additionally, some procedures, such as EDM, have implemented the optical-line follower system in 1974 (Jameson, demonstrated the ability to create intricate characteristics with an 2001). As the industry developed a better understanding of the excellent precision and an appropriate productivity (Thomas and procedure and its possibilities by 1975, the procedure’s popularity Gilbert, 2015). increased quickly (Benedict, 1987). The implementation of the Manufacturing devices with complex forms and proﬁles uses the computer numerical control (CNC) system into WEDM at the tail commonly developed unconventional material removal technique end of the 1970s was the only factor that signiﬁcantly advanced the known as WEDM. It is thought of as a unique version of the process of machining. Because of the wire that needs to pass through conventional EDM technique, which initiates the sparking the component to be machined, the WEDM process’s considerable operation using a metal electrode. In order to attain the smallest capabilities were therefore heavily utilized. WEDM is frequently used corner radii, WEDM uses a continuous moving wire electrode made to create prototypes, aircraft and medical accessories, stamping and of copper, brass, or tungsten (W) that has a diameter of extrusion tools and dies, ﬁxtures and gauges, and grinding wheel 0.05–0.3 mm. The possibility of producing inaccurate parts is form tools. reduced by using an automated adjusting system to maintain the An enormous amount of energy is expended in mechanical- WT. The mechanical tensions associated with machining are based chip removal operations to remove undesired chips that must removed throughout the WEDM operation because the material be disposed (Jebarose Juliyana and Udaya Prakash, 2022). However, is machined ahead of the wire and there is no physical contact the substantial amount of cutting energy results in undesirable heat, between the component being machined and the wire. The WEDM which may result in issues with SR, surface cracking, and technology also eliminates the dimensional shifts that happen deformation (Naeim et al., 2023). Additionally, residual tensions during the machining of heat-treated steels and can work with and burrs may be created throughout the process of machining, high strength and temperature resistance (HSTR) materials. The which would primarily call for additional post-processing schematic representation of Wire EDM process is shown in Figure 1. operations (Malakizadi et al., 2022). It is important to note that WEDM is one of the most often utilized unconventional typical machining techniques like turning, drilling, shaping process, machining techniques because of its lower cost, higher and milling are challenging to use when machining superalloy dimensional accuracy, and greater surface polish. It is a non- materials with excellent strength and resistance to wear contact type non-traditional machining process. Consequently, (Goiogana and Elkaseer, 2019). Due to this constraint, un- there are no mechanical stresses placed on the specimen or the conventional machining methods have emerged that have the tool. Inconel, Ti, as well as other high strength, temperature- ability to produce components with intricate characteristics in resistant nickel-based alloys are a few examples of materials that superalloy materials, in addition to their excellent mechanical are highly tough and challenging to manufacture using traditional and thermal characteristics (Pramanik, 2014). cutting techniques. These materials are often utilized in the aircraft, Un-conventional machining methods for production can be submarine, nuclear power, and rocket sectors. For cutting of such characterized as a collection of procedures that eliminate excess materials, the EDM method was therefore recognized as a potential material using a variety of methods based on mechanical energy, technology (Ho et al., 2004; Jahan et al., 2011; Maity and Mishra, thermal energy, electrical energy, chemical energy, or even a 2016). It is an electro-thermal machining technique when heat is combination of these energies without the use of cutting tools produced by an electrical spark across the tool and the specimen. with sharp edges to remove chips, as is the case in conventional Removal of materials happens as a result of the material melting and mechanical manufacturing techniques. In order to fulﬁll the needs of vaporizing (Soni, 1994; Yadav et al., 2002). the ﬁnal products to be manufactured, a number of unconventional Micro-EDM and EDM operate on very similar principles. With machining techniques have been created (Alting and Boothroyd, a tool that is considerably smaller than normal and discharge energy 2020). Practically, in comparison with traditional machining that is at a micro scale. A tiny gap exists between the tool and the Frontiers in Mechanical Engineering 02 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 FIGURE 1 Schematic representation of Wire EDM Process. specimen during EDM. When a DC voltage applies across them, a electrode/wire materials, including brass, copper, and composite strong electric ﬁeld is created in the space. The impurities in the wires (Kruth et al., 2004a; Kapoor et al., 2012; Chen et al., 2022), dielectric ﬂuid are drawn to this electric ﬁeld and concentrate where were studied in the past. Likewise, efforts to optimize process it is highest. As the ﬁeld voltage rises, these contaminants create a variables are given in order to minimize tool wear and enhance highly conducting bridge over the gap. When heated, some of the the SR. The efﬁciency of the wire-EDM process still has to be particles in the conducting bridge spanning the space create a ﬂash improved due to the slow rate of material cutting, inability to path between the tool and the specimen. As temperature and produce clean corners, high expenses, and lack of enormous scale pressure in the channel increase at this stage, a little amount of manufacturing capacity (Jain et al., 2021). material melted and evaporates from the tool’s surface and the Additionally, by using environmental friendly di-electric specimen at the point of lightning contact (Muthuramalingam and substances like puriﬁed water, it also satisﬁes a green approach. Mohan, 2015). Following sparking, the dielectric medium is used to Further enhancing dimensional precision and machining efﬁciency wash out any debris particles that have accumulated on the is the fact that the wire’s continuous movement has no uneven machining surface. One of the main difﬁculties in the EDM effects on the surface being machined (Annebushan et al., 2020). process is cleaning the electrode gap of debris. When metal However, for lower MRR, the surface quality is signiﬁcantly higher. melts, debris that results from this accumulation builds up in the Above a speed of 2.65 mm/min, the cutting speed (CS) also gap, and the process is poorly ﬂushed, it becomes unstable and proportionately reduces the SR, with severe degradation negatively impacts the MRR and SR (Liao et al., 2013). (VishalSharma et al., 2023). Tool wear occurs when strong It is essential to enhance the electric process in order to improve composites are processed using traditional methods (Ishfaq et al., the effectiveness of the method since the amount of thermal energy 2020). Often the machine settings provided by the manufacturer generated is proportional to the input electrical power. Different don’t meet the requirements or give the manufacturing engineers the ﬂushing approaches, dielectric alterations, the use of magnetic ﬁelds, right direction. A correct choice of WEDM process variables is different types of dielectrics, electrode coating, etc. are just a few of therefore necessary, for this reason only many optimization the methods researchers have devised to increase process efﬁciency. techniques were applied to ﬁnd the optimum process parameters However, the use of these strategies is constrained by the uncertainty (Ho and Newman, 2003; Udaya Prakash et al., 2021a). of the EDM mechanism. One technique used to enhance ﬂushing In the present study, a comprehensive review on the effect of during the EDM process is vibration of the tool or specimen. Clean various wire EDM process parameters for obtaining larger MRR, dielectric is drawn into the gap as the tool or workpiece goes either minimum SR, K , and wire wear were studied along with the various upward or downward, and the debris is driven out of the cutting gap optimization methods used. This article will be useful to the budding when those movements occur. researchers to know about the various wire EDM process parameters, This manuscript summarizes the most recent research on different wire electrode materials and their impact on the responses. WEDM that have presented their ﬁndings. In the past, wire The paper focuses on the key WEDM studies, which include process EDM has been effectively used on materials such as metals, optimization and monitoring and control for WEDM. The paper’s alloys and composite materials (Lok and Lee, 1997; Ming et al., conclusion examines these subjects and makes recommendations for 2020). For higher machining rates and better SR in WEDM, several the direction of future WEDM research. Frontiers in Mechanical Engineering 03 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 2 Literature survey peak current, SR and MRR are examined and demonstrated. T has on a signiﬁcant impact on SR and MRR, and AA5083 has superior MRR Titanium (Ti) and its alloys are difﬁcult to process and and SR than AA6061. The output parameters such as MRR, surface uneconomical while utilized in conventional machining ﬁnish, and overcut were explored in similar machinability tests on techniques due to its reactivity with chemicals as well as low AMCs. Since it determines the geometric precision of components thermal conductivity (Hong et al., 1993). In many sectors, with complex shapes and sizes, the overcut is the most crucial WEDM is utilized to machine with exceptional accuracy and variable for numerous uses. Recent advances in material provide an outstanding surface ﬁnish, is frequently used to deal development necessitate improvements to the machining process with these hard materials. WEDM is a powerful machining and optimum parameters, because each machining method has technique that uses thermo-electric energy for material removal drawbacks and performance requirements, choosing the right during cutting (Jebarose Juliyana et al., 2022a). production process for any product is a difﬁcult task (Ghaleb Ti-6Al-4V was chosen as the specimen by (Klocke et al., 2011), and et al., 2020; Ozcalici and Bumin, 2020; Sadhana et al., 2020; a brass wire as the electrode. The SR was predicted and modeled using a Basak et al., 2021). two-level factorial approach. The process variables were V, pulse-on MRR, surface roughness, and kerf are the three vital output time (T ), dielectric ﬂuid pressure (P), and pulse-off time (T ). The parameters that need to be controlled by selecting the best input on off ﬁndings demonstrated that with shorter T duration and at less P, a parameters when performing WEDM. The surface quality improves on superior surface ﬁnish could be achieved. This specimen was examined the materials’ fatigue strength, resistance to corrosion, and fracture as a potential specimen by (Alis et al., 2012). A titanium alloy was toughness, and it also decreases friction, as can be seen in (Udaya machined using brass wire and a steady 4A current. The WT, S, and Prakash et al., 2018a). A high GRG value will enhance productivity. discharge current were chosen as the machining variables. Based on The SR becomes worse when the pulse period increases, while the SR their investigations, they concluded that raising the current produced a declines with a hike in the discharge current or load current factor higher MRR and that raising the WT produced a surface with a smooth and ﬂushing pressure. With a higher current, T , and GV, the on ﬁnish. Additionally, it was noticed that as WT increased, the vibrations surface roughness of composites rises (Udaya Prakash et al., 2018b). of the wire decreased. A Ti-6Al-4V alloy was machined using WEDM The kerf, or cutting width, determines the dimensional stability of technique by (Gupta et al., 2019)withconstant6Acurrentand variable the ﬁnal parts. The kerf increases with the peak current and machining speeds between 2 and 6 mm/min. The process variables decreases with the tool travel speed and pulse on time when included the pulse duration, wire speed, servo voltage (SV), WT and F. cutting hybrid composites. The output response is the MRR and SR. The SV is of 60 V, the WT of For relating the major process variables of WEDM with rough cut 1.4 kg, the S of 8 m/min, and the F of 4 mm/min produced the most proceeded by trimming cut using RSM (Puri and Bhattacharyya, favorable results. At a lower machining F and a greater WT, the surface 2005), created mathematical models of the white layer. The condition was satisfactory. It was discovered that some process investigation used a second order spinning central composite variables, such as wire speed and pulse duration, had lower MRR. design with four different parameters, including T in rough on (Singh et al., 2018) formulated an ANFIS model for Wire-EDM cutting, T in trim cutting, offset, and CS with 5 levels (Iqbal and on of ballistic grade aluminium alloy with process parameters such as Khan, 2010). employed the response surface approach to investigate pulse on time (T ), pulse off time (T ), peak current (I ), and servo the connectivity and varying interactions among the metrics of on off p voltage (SV). Material removal rate (MRR) is employed as process performance used in EDM milling, such as MRR and SR. ANOVA performance evaluator. The values predicted by the developed is used to identify statistically signiﬁcant coefﬁcients for the model are found closer to experimental outcome and thus coefﬁcients of the model of the variables. To illustrate the ensures the model suitability for prediction purpose and quantitative impact on the process outputs of WEDM, such as intelligent manufacturing. MRR, SR, and kerf (Saurav and Sankar, 2010), developed quadratic Wire EDM was implemented by (Hou et al., 2022) to investigate mathematical representations. With many possible combinations of the surface features of Ni-Ti shape memory alloy, including surface variable applications the RSM is used for predicting process responses. damage, shape recovery ability, and hardness. According to the The predicted data is employed to compute the best set of variables for researchers, the roughness dropped from 2.79 µm to 0.12 µm. The attaining the highest MRR, dimensional precision and the minimum Taguchi approach was applied by (Mathew Paulson et al., 2022) SR. Using RSM (Kumar et al., 2012), examined WEDM of pure Ti by examined titanium to attain the largest MRR and the least amount of simulating the responses such as SR, machining rate, dimensional SR. The two features of the output mentioned above are directly precision, and wire wear ratio. The Box-behnken design was used to inﬂuenced by the peak current (I ) rise, and the T shows a similar conduct the experiments, which involved modifying variables like T , p off on trend. The grey relational analysis reported the ideal peak current of T , GV, I, WT and F. The responses were then optimized using off 3A, and the obtained T and T times were 30 µs and 9 µs, desirability approach, and the validity of the model was conﬁrmed by on off respectively. Brass and coated electrodes of 3 different diameters ANOVA. RSM was used by (Shah et al., 2013) to optimize the process were used in (Kupper et al., 2021) comparable assessment of steel variables in WEDM of Inconel-600.Taguchi’s robust design suggests wire-EDM at various heights. an experimental strategy, and Taguchi’s Mixed L OA has been used Al6061 with MoS was machined by (Rani et al., 2017) using the for the experiments. The response was optimized in regard to MRR by WEDM method, and it was found that the F and T greatly affected taking into account the input variables such as T ,T , I, and wire off on off the SR, while the peak current and T had an impact on the MRR. feed rate. The impact of the machining variables on the output of on In WEDM machines (Saif and Tiwari, 2021), studied the machining WEDM is studied using ANOVA, and a RSM has been created for capabilities of AA6061 and AA5083. In relation to T ,T , and studying MRR. on off Frontiers in Mechanical Engineering 04 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 (Choudhary et al., 2018) investigated the machining performance of the wire electrical discharge machining (WEDM) performance of Al6061/14% ﬂy-ash composite about the inﬂuence process. One of the unconventional machining techniques is of pulse current, T , applied voltage, and duty factor in the EDM WEDM. Using Minitab-17’s linear regression analysis, a on process. MRR of the specimen increases as the current, duty cycle, and relationship was formed between the process parameters and the T increase. Tool electrode shift decreases with an increase in voltage output responses. The Taguchi L orthogonal array was required on 25 from copper to brass. Also, with an increment of current and T , for the experiments that were conducted. The material removal rate, on TWR increases. As the duty cycle, T increases, the SR increases. cutting speed, and surface roughness were all taken into account on Moreover, SR initially decreases with the current but then increases. when machining composite materials; the kerf was not included in Due to the carbon layer deposition, the copper electrode TWR is not the study (Shadab et al., 2019). signiﬁcant. However, it is important due to carbon layer unavailability Only single output problems can be resolved using the Taguchi present on the brass electrode. 0.1996 g/min of maximum MRR was approach. Multi response optimization is a fascinating optimization observed in the tool electrode of brass at 150 μsT ,and acurrent of approach that seeks for the most suitable response to any problem or on 16 A, owing to its higher current gap, dissipates heat energy at the activity by simultaneously considering into account a number of workpiece. At a GC of 16 A and T of 150 μs in the electrode of the responses. GRA reduces multi-response systems to single-variable on brass tool, the maximum TWR was 0.0770 g/min because of the soft problems and then ﬁnds effective solutions. Determined, material of brass and the release of energy (Maniyara and Ingole, insufﬁcient, or unclear data problems can be resolved using 2018). studied the EDM parameters in multi-response optimization Deng’s proposed Grey theory (Glad and Etienne, 2003), which for the aluminium hybrid composites based on the grey relation can also be used to investigate the correlation between process approach in which the mixed equal wt% of silicon carbide and factors and ﬁndings (Sarala Rubi et al., 2022a). graphite had the most signiﬁcant compared to other process parameters, and current of 4 amps, SiC- Gr of 15 wt%, and T of on 500 μs were identiﬁed as the optimal parametric conditions (Yan et al., 3 Wire EDM parameters 2000). analyzed the machining characteristics of Al O /6061 Al 2 3 composites during rotary EDM. The higher MRR is reached with Based on the responses such as MRR, kerf width, SR, etc., the the dislike electrode, although the TWR is higher, and MRR is affected WEDM’s performance is analyzed. The input process variables such mainly by the polarity of EDM. as T ,T , V, F, etc. have a signiﬁcant impact on these responses. on off (Muniappan et al., 2018; Muniappan et al., 2019) investigated The cause and effect diagram (Fish Bone diagram) for several the cutting speed parameters on WEDM by multi-objective performance measurements in the WEDM approach is shown in optimization on SiC and graphite-reinforced Al6061 hybrid Figure 2 (Vijayabhaskar et al., 2018). composite using Taguchi’s method. The stir casting was selected as the fabrication method in their work due to its good wettability characteristics, uniformity in the dispersion of reinforcement 3.1 Pulse on time and pulse off time materials by stirring action, high processing temperature and low cost compared to other methods like powder metallurgy and spark Throughout the cutting process, electric discharge machining plasma sintering (Umasankar et al., 2014; Juliyana et al., 2022; must start and halt periodically. When the pulse is turned on, a “V” Udaya Prakash et al., 2023a; Udaya Prakash et al., 2023b; is transmitted to the region among the specimen and the wire, but Narendranath and Udaya Prakash, 2023). when it is turned off, no voltage is applied. As a result, electric (Sivaprakasam et al., 2022a; Sivaprakasam et al., 2022b) discharge is only observed during the ON time. It would be feasible examined at how responses like MRR and SR during WEDM of to choose a high value of ON time in order to have a discharge that HSLA were affected by variables including T ,T , SV, I, and WT. lasts for a long time, but performing so could result in a short circuit on off To optimize the process variables, a mathematical model using RSM and wire breaking. The OFF time needs to be entered as shown in and the central composite rotatable design (CCRD) is developed Figure 3 to avoid this problem (Mouralova et al., 2019). (Lakshmanan and Kumar, 2013). carried out WEDM on EN 31 tool steel in order to compare the machining variables with the outputs. The process’s performances were modeled using a response surface 3.2 I and GV approach, and the accuracy of the model was checked using ANOVA (Majhi et al., 2013). hybrid optimization technique was “I” is one of the most important machining parameters in proposed for determining the best process variables, such as T , WEDM. It measures in amps and represents the power on T , and pulse current, in order to maximize MRR while minimizing consumed by WEDM. The peak current is reached when the off tool wear rate and SR. The ﬁndings of the designed experiments are current surpasses the speciﬁed threshold for each pulse on-time. used in the GRA. Based on the outcomes of optimization, the RSM The maximum current in wire-EDM and die sinking procedures is displayed the impact of the process parameters on the responses. determined by the cut’s surface area. Roughing operations and the According to Malik Shadab et al., the existence of features with vast surfaces demand a higher current. The input reinforcements makes them challenging to machine to meet voltage to be applied to the gap is speciﬁed by the GV or open circuit industrial standards. Consequently, in order to increase output voltage. These variables are typically not independent of one performance in terms of product quality, the machining process another. In simpler terms, the “I” automatically increase as the parameters must be optimized. Several factors, including T ,T , GV does. Both of these variables exhibit cutting voltage on certain on off induced current, and WF, have an impact on the overall WEDM equipment (Udaya Prakash et al., 2023c). Frontiers in Mechanical Engineering 05 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 FIGURE 2 Cause and Effect diagram for WEDM Process. FIGURE 3 Pulse on time and pulse off time. 3.3 SV and SF specimen and the wire gets more depending on the value for SV. Higher SV values slow down the rate of machining while simultaneously The wire’s expansions and retractions are controlled by variable reducing the quantity of electric sparks and regulating the electric servo voltage (SV). The average processing voltage varies during discharge. The average gap gets narrower when SV is set to a lower machining based on how well the specimen and electrode are being value, which causes more electric sparks to occur. It can increase the rate machined. SV supplied the reference voltage for regulating the wire’s of machining, but the machining parameters at the gap could change, forward and backward motion. The wire moves forward and retracts leading to wire failure. The table’s feed rate while machining is also depending on whether the average cutting voltage is greater or lesser regulated by the servo feed rate (SF). The WEDM equipment typically than the predetermined voltage level. As a result, the space among the chooses this variable based on the SV automatically, however this Frontiers in Mechanical Engineering 06 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 conduction is desirable because it can transport larger amounts of electricity, resulting in a “hotter” spark and more rapid cutting. Tensile strength (TS) is a measurement of a wire’s ability to cope with stress placed on it during machining in order to produce a vertically straight cut. Elongation is a term used to indicate how far a wire undergoes plastic deformation before breaking. By increasing the wire electrode’s melting point, we are able to render it less probable that it will melt prematurely from electrical sparks. Straightness could play a role in the wire remain straight. Better ﬂushability means the wire will cut more quickly and there will be less possibility of wire breakage (Kern, 2007). 3.8 Dielectric type The choice of dielectric is more crucial. The hardness and chemical make-up of the specimen are affected by the recast layer because various dielectric materials cool at different speeds FIGURE 4 and have distinct chemical composition. Numerous studies have Wire drag and Wire Tension. examined into how various kinds of dielectric affect the effectiveness of WEDM. Researchers have recently looked into how well the WEDM technique performs when employing powder mixed variable may be set directly. In this situation, the cutting table runs at a dielectric (Chaudhari et al., 2024). ﬁxed rate regardless of the SV (Gupta et al., 2021). 3.9 Flushing technique 3.4 Dielectric ﬂow rate Due to the geometrical variations of WEDM, the type of ﬂushing Although electro discharge can happen in the atmosphere, it is that is used is a crucial process variable. In WEDM, the dielectric not unstable and unsuitable for rough cut machining. Dielectric ﬂuid is only cleans the gap of debris but also affects how well the process necessary for steady electric discharge. Electric discharge machining works. Pressure ﬂushing, jet ﬂushing, and suction ﬂushing are just a can be regulated inside the dielectric ﬂuid with effective chip few of the different types of ﬂushing methods employed in WEDM. removal and cooling. In wire EDM, de-ionized water is To have higher machining efﬁciency, choosing the right ﬂushing commonly used as a dielectric due to its low impact on the technique is essential (Singh et al., 2023). environment. For instance, because Ti alloy has a low thermal conductivity, it is extremely important to employ a high ﬂushing pressure during rough machining to prevent wire breakage from the 4 Different wire materials short circuit occurrence (Raju et al., 2022). 4.1 Copper 3.5 S or F Copper was the initially developed substance used in wire EDM. Although it has an outstanding conductivity rating, its potential was The crucial measure in WEDM that displays the S is wire speed. severely constrained by its high M.P, and low vapor pressure value. Though lower S can result in failure of wire at high machining speeds, increasing S also increases wire consumption and, as a result, machining costs (Kumar et al., 2021). 4.2 Brass Copper and zinc are combined to create brass EDM wire, which is 3.6 Wire tension commonly alloyed with 63%–65% Cu and 35%–37% Zn. The relative conductivity losses are more than made up for by the inclusion of zinc, The element that controls wire tension in WEDM is WT. If the which also has a low M.P and a greater vapor pressure. Brass is rapidly WT is sufﬁciently high, the wire remains straight; otherwise the wire moving to the very forefront of the list of electrode materials used for drags, as seen in Figure 4. general-purpose WEDM (Ceritbinmez et al., 2023). 3.7 Wire type 4.3 Coated wires When WEDM was initially developed, the key issue was the wire The creation of coated wires, also known as plated or “stratiﬁed” substance, which should have many characteristics. A wire with a high wire, was the natural next step because brass wires cannot be Frontiers in Mechanical Engineering 07 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 economically manufactured with a larger percentage of zinc. For 5 Different responses conductivity and tensile strength, they normally feature a brass or Cu core. For improved spark generation and ﬂush properties, they 5.1 MRR and cutting speed are electroplated with a coating of pure or diffused Zn. Coated wires are currently available in an extensive range to meet varied machine Various strategies to accelerate the MRR and cutting speed have needs. Currently, coated wires offer the best performance been investigated in many investigations. Stopwatch was used to characteristics but are costlier than brass. record the machining time, and Eq. 1 is used to calculate the MRR (Antar et al., 2011) provided the specimen productivity and (Zhang et al., 2019; Zhang et al., 2020). integrity when WEDM titanium alloy and Ni based super alloy, it MRR LHK t(1) was possible to increase efﬁciency by about 40% for Ti alloy and about 70% for Ni based super alloy. Better outcomes were obtained Where, L is the cutting length, H is the work piece thickness, and when employing coated wire for both roughing and trimming t stands for the machining time (Chen et al., 2022). operations with regard to recast layer thickness. Actually, it has (Rajurkar and Wang, 1993) used an experimental investigation been possible to make Ti alloy that is approximately 40% thinner to analyze the wire breakage mechanisms. It has been found that a and Ni-based super alloy that is about 25% thinner with coated reduction in T causes an initial increase in the MRR in WEDM. off wire machining. However, the gap becomes unpredictable at a very small T , which off In another investigation (Poros and Zaborski, 2009), observed lowers the machining rate. According to (Singh and Garg, 2009) that a raise in discharge duration can considerably impact analysis of the impact of machining variables on MRR in WEDM, machining speed and MRR by 62% for electrodes made of brass MRR increases with increases in T and “I” but decreases with on wire and by 138% for electrodes made of zinc-coated brass wire. increases in T and SV. These ﬁndings coincide with those made off When there is a pulse, the zinc overheats and evaporates. By acting accessible by (Yu et al., 2011). According to Poro’s and Zaborski’s as a heat sink, evaporation lowers the temperature of the wire, investigation into the impacts of wire and specimen on WEDM enhancing the efﬁciency of the WEDM process. Consequently, as efﬁciency, WEDM performance would decrease as speciﬁc heat more powerful heat ﬂuxes are enabled, the cutting speed rise up to capacity of machined materials increase. 50% (Prohaszka et al., 1997).The coating evaporation also widens In another investigation, an effort was made to identify the the gap and leads to greater debris removal, which could decrease the essential machining variables for WEDM efﬁciency metrics such as SR and the sparking gap (Dauw and Albert, 1992). MRR, SR, and kerf width. In order to maximize MRR during rough However, the sparking gap and SR also degrade due to the zinc- cutting operations, it has been observed that variables including coated wire’s faster cutting speed. Composite wires have replaced discharge current, pulse duration, and dielectric ﬂow rate, as well as zinc-coated wire as the preferred wire for specimens. The Composite their interactions, play a major role. The inﬂuence of work piece wires contain a core made of plain carbon steel that is encased in a thickness on the MRR was studied by (Shah et al., 2011). It has been layer of pure copper and ﬁnished with zinc-enriched brass on the predicted that this variable would be substantial, however their outside. Still, copper-clad steel wires function better for large work research indicates that specimen thickness is not an inﬂuencing pieces (Kapoor et al., 2010). Furthermore, Kruth et al. (Kruth et al., factor for MRR. The several possible effects on the WEDM 2004b) observed that composite wires with a high tensile core can performance indicators were divided into ﬁve main groups by greatly improve accuracy, particularly in edge cutting. Diffusion (Konda and RajurkarBishuGuhaParson, 1999). According to the annealed wires outperform ordinary wires signiﬁcantly in terms of idea, increasing the peak current can make each discharge more resistance to wire breakage. energetic and result in craters that are broader and deeper and have a higher MRR. Additionally, extending the period of each discharge may improve the rate of MRR by increasing T on 4.4 Fine wires Numerous studies support these hypotheses, such as the one provided by (Tosun et al., 2004) which examined the optimization of The typical range for wire sizes is 0.006–0.0012 inches. Wire machining variables and their impact on the kerf and MRR. ANOVA diameters between 0.001 and 0.004 inches are required for high was used in this study to evaluate the inﬂuence of the machining precision operations on wire EDM machines with small inner variables on the MRR. S and dielectric cleansing pressure were shown radii (Ghodsiyeh et al., 2013). Due to their poor load bearing to be less effective, however open circuit voltage and pulse duration capacity, coated and brass wires are unattainable, so Mo and were found to be extremely effective characteristics. This study found tungsten wires are utilized instead. They are not recommended that the second ranking element was around six times less signiﬁcant for particularly thick work, however, have a tendency to cut than open circuit voltage for regulating the MRR. slowly due to their low conductivity, high M.P, and low vapor pressure ratings. Only a couple of scientiﬁcstudies have dealt 5.2 Surface roughness with cutting by WEDM employing wires smaller than 50 µm in diameter. The wires are made of brass-coated steel wire and Numerous studies have attempted to reduce SR in various ways. tungsten, a metal with a high M.P and T.S. The common thickness of ultra-thin wires is 20, 25, 30, and 50 µm. With According to the hypothesis, cutting speed and SR have an inverse wire-EDM, these wires can be used to create small connection, and SR is greatly inﬂuenced by the T and peak current. on components (Klocke et al., 2004; Ilić et al., 2020). The According to studies conducted by (Sarkar et al., 2008), SR diminishes commonly used wire material is depicted in Table 1. as cutting speed rises. According to multiple studies, the most Frontiers in Mechanical Engineering 08 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 TABLE 1 Commonly used Wire Material in WEDM. S.No. Wire Material Input Responses Design/ Observation Author/ material used variables Optimization Year method 1 SS-304 Copper Al/SiC/Gr Pulse off time (T ) Material removal Response surface � The integrated Abbas et al. off Brass Composite rate (MRR) and methodology (RSM) and approach of (2023) tool wear complex proportional RSM–COPRAS rate (TWR) assessment (COPRAS) and suggested that the machine learning methods optimized settings for MRR and TWR are Ton: 60; Toff: 60; V: 7; I: 12; and tool: brass Pulse on time (T ) � The maximum TWR on was observed in the Servo voltage (SV) case of brass, followed by those of Cu and Current (I) SS-304 Tool electrode 2 Molybdenum Mg-Zn-RE-Zr Current, Pulse-on Surface Roughness Central Composite Design � The statistical analysis Sheth et al. wire with alloy time, Pulse-off time (CCD) based response based on ANOVA (2020) 0.018 mm Wire feed rate surface methodology (RSM) results led to conclusion diameter and PVS algorithm that for WEDM process, pulse-off time is least inﬂuencing parameter while pulse- on time and current are dominating control parameters � Higher values of pulse- on time and current generate rougher surface due to the formation of large crater on surface 3 Single-strand Inconel 825 Pulse-on time, Material removal RSM based Desirability � It was concluded that Kumar et al. plain brass wire (150 mm × Pulse-off time, Peak rate approach pulse-on time, gap (2019) of diameter 150 mm × current, Spark gap voltage and peak 0.25 mm 10 mm) voltage current have signiﬁcant positive effect on Wire tension, Wire Surface roughness increasing MRR while feed Wire wear ratio increase in pulse-off time resulted in decreased SR. 4 Zinc coated A413 with Pulse on time, Pulse Material removal Central Composite Design � The statistical analysis Soundararajan brass wire of 12 wt% B C) off time, Peak rate and Surface (CCD) based RSM. based on ANOVA et al. (2020) 0.25 mm Composites current roughness prediction is the most diameter signiﬁcant one for dominating control parameters like T and on I than least inﬂuenced parameter of T on off more MRR and T off signiﬁcantly directs the better SR in WEDM process based on their contribution 5 Brass wire High strength Pulse on time, Pulse Metal removal rate Response Surface � With the increase in the Sharma et al. low alloy steel off time, Peak and Surface methodology (RSM) value of T surface (2013) on (HSLA) current Servo roughness roughness increases voltage � Higher value of T and off SV, Lower value of I favours the surface qualities (Continued on following page) Frontiers in Mechanical Engineering 09 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 TABLE 1 (Continued) Commonly used Wire Material in WEDM. S.No. Wire Material Input Responses Design/ Observation Author/ material used variables Optimization Year method 6 Brass (Dia: Al/SiC/Ti Pulse on-time Pulse Cutting speed (CS) RSM based Box Behnken � The statistical Khanna et al. 0.25 mm) Hybrid off-time Servo and kerf Design (BBD) and Teaching investigation suggests (2022) composite voltage Wire feed width (K ) learning based optimization that for CS the most material (TLBO) inﬂuential factor is Ton; however, for KW this factor is SV. 7 A 0.25 mm LM5/ZrO2/Gr Wire feed, Pulse on- MRR, Surface Grey Relational Analysis � The experimental Jebarose diameter brass Hybrid time Pulse off-time roughness (SR) ﬁndings and GRA show Juliyana et al. wire composite Gap voltage, that the optimum (2023) Kerf width (K ) material Reinforcement w process parameters for percentage achieving the highest GRG are 6% ZrO with 2% graphite reinforcement, a wire feed of 6 m/min, a T on of 110 µs, a T of off 40 µs, and a GV of 20 V 8 A 0.25 mm AISI 1045 steel Pulse on-time Pulse Material removal ANN � The optimal conditions Alduroobi et al. diameter brass off-time Servo rate (MRR) Surface for maximum MRR (2020) wire feed (SF) roughness were: T at level-3 on (25 Ls), T at level-1 off (20 Ls), and SF at level- 3 (700 mm/min) � The optimal conditions for minimum SR were: T at ﬁrst level (10 Ls), on T at the third level off (40 Ls), and SF at ﬁrst level (500 mm/min) important factor inﬂuencing SR is the T .The “double sparking” effect Bhattacharyya, 2003). also investigated the k and discovered that on w causes the SR to rise as the pulse on time does. Therefore, as the T only GV affects k signiﬁcantly, while T and T have little to on w on off grows, double sparking and localized sparking occur more frequently. A no impact. poor surface quality is produced by double sparking. These ﬁndings coincide with those provided by (Udaya Prakash et al., 2020). 5.4 Wire wear ratio 5.3 Kerf width and spark gap Researchers have explored many methods to reduce the WWR. Because this component has the potential to signiﬁcantly reduce the The quantity of material lost during machining is measured phenomenon of wire rupture. by k . The internal corner radius of the product and the ﬁnishing The WWR is often calculated using the Eq. 3. part’s dimensional correctness can be determined by it, however WWR WWL/IWW (3) WEDM processes are also constrained by this factor (Parashar et al., 2010). Where, WWL is the weight loss of wire after machining and SG value is often calculated using the Eq. 2. IWW is the initial wire weight. In order to determine how various WEDM conditions will affect wire lag during the rough cut and Spark gap() mm average of k −diameter of wire2(2) trim cut processes (Kuriakose and Shunmugam, 2004), explored into this. During rough cutting, it emerged that T ,T ,and I; and There are various contradictory studies on the impact of on off during trim cutting, V, WT, and SV; are the most dielectric ﬂushing pressure, peak current, and T duration on k . off w inﬂuencing variables. (Swain et al., 2012) examined the impacts of WEDM variables on k while cutting stainless steel, it was observed that the most important variables are T and dielectric ﬂushing pressure, while on 5.5 Wire lag and wire EDM inaccuracy gap voltage, T , and wire feed had less of an impact. Tosun et al. off (2004) used ANOVA to present their analysis into the inﬂuence of Whenever intricate shapes with exact speciﬁcations must be machining variables on k . S and dielectric cleansing pressure were created, WEDM is highly helpful. Geometrical errors are wholly shown to be less impact, however open circuit voltage and pulse duration were found to be highly efﬁcient characteristics (Puri and unacceptable in this situation. Due to the potential for geometrical Frontiers in Mechanical Engineering 10 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 imperfection induced by these phenomena, some studies attempted 6.2 Wire inaccuracy adaptive to reduce wire lag. However, there is still little of knowledge control systems regarding this fact. The accuracy of contour cutting using WEDM can be improved with more investigation into wire lag. One of the most unfavorable features of machining is the possibility (Newton et al., 2009) investigated the effects of different of wire breakup during WEDM, which has a signiﬁcant impact on cutting parameters on surface characteristics of Ti6Al4V. It is observed precision and efﬁciency as well as the quality of the item manufactured. that more uniform surface characteristics are obtained with coated There have been numerous attempts to create an adaptive control system wire electrode. Furthermore it was found that pulse off time is the that can identify any inappropriate machining conditions live and use a most sensitive parameter that inﬂuences the formation of layer control strategy to keep the wire from breaking without compromising consisting of mixture of oxides. With a lower value of pulse off the various WEDM performance metrics. time, a considerable reduction in the formation of oxides can be obtained. (Ramakrishnan and Karunamoorthy, 2006) have studied the 6.3 Self-tuning adaptive control systems effect of process parameters on the formation and characteristics of recast layer and in term of recast layer it was found that the peak WEDM research and development has been focusing on control discharge current and pulse on time to be the driving factors in systems that can adapt to changes in the power density needed to determining average recast layer thickness and pulse off time and machine a specimen with varied thickness. Several authors wire diameter did not display a signiﬁcant effect on average recast (Tanimura et al., 1977; Kunieda et al., 1990; Shoda et al., 1992; layer thickness. Rajurkar et al., 1994) discovered that altering the workpiece thickness while machining causes the thermal density of the wire to rise and eventually cause the wire to break. According to the 5.6 Surface integrity electronically identiﬁed workpiece height (Rajurkar et al., 1997; Yan et al., 2001), suggested adaptive control system with a multiple input SR, Recast layer thickness, and surface cracks should all be taken model monitors and regulates the sparking frequency. When into account while trying to enhance the surface integrity of the machining a work piece with adjustable height, Yan et al. WEDM approach. High MRR and high R values could go together (Snoeys et al., 1998) used fuzzy control logic to prevent wire with good grade of SR (Boccadoro and Dauw, 1995). breakage and neural networks to estimate the workpiece height. In order to monitor and manage the WEDM process (Huang and Liao, 2000), presented a knowledge based system that consists of three 6 WEDM process monitoring modules: task preparation, process control, and operator support or and control fault diagnostics. The WEDM machine is thus granted a greater degree of ﬂexibility because of the capacity of these modules. The This section examines the cutting-edge monitoring and control signiﬁcance of the operator support and defect diagnostics systems for systems employed in the WEDM process, such as the fuzzy, wire the WEDM process has also been mentioned by (Dekeyser et al., breakage, and self-tuning adaptive control systems. 1988). A working model of an ANN based expert system was suggested for the WEDM’s routine upkeep and fault diagnosis. For forecasting and managing the thermal overload experienced on the 6.1 Fuzzy control system wire (Prakash et al., 2021), created a thermal model coupled with an expert system. Although the approach increases machine autonomy, it In recent years, the WEDM process has been optimized and necessitates a lot of calculation, which slows down processing and made more effective by applying the fuzzy control system. reduces the effectiveness of online control. According to a number of publications, the fuzzy control system employs an approach to maintain the desired machining operation that takes into account the expertise of the expert or the 6.4 Design of experiments (Taguchi method) operator (Yan et al., 1999). Additionally, no complicated mathematical models are needed for the fuzzy logic controller Taguchi method used to design the experiments, by using the to adapt to the unpredictable behavior of the WEDM method (Liao orthogonal array, to help researchers to have balanced experiments that and Woo, 1998). In order to be applicable to a variety of machining consider the effect of process parameters with their levels on the process options, many authors (Liao and Woo, 2000) presented the performance measures, i.e., using Taguchi method will help to collect all sparking frequency monitoring and adaptive control systems necessary data to understand which factors have the major effect on the based on fuzzy logic control and the adjusting techniques. A product quality by using a minimum number of experiments fuzzy controller with an online pulse monitoring system for (Stojanovic and Ivanović,2014; Ananth et al., 2020). The separating the discharge noise and differentiating the ignition ‘‘orthogonal array is represented by L , where the subscript a a(bc) time delay for every pulse was also developed by (Cogun, 1990). represents the number of parameter combinations, b represents the The classiﬁcation of EDM pulses into open, spark, arc, off, and number of control factor levels, and c represents the number of control short pulses, which rely on the ignition delay time and directly factors. The control factors are the parameters that may inﬂuence the affect the part’s MRR, SF, electrode wear, and accuracy (de Bruyn quality characteristics, i.e., performance measures’’ (Ugrasen et al., and Pekelharing, 1982; Kinoshita et al., 1982). 2014b; Udaya Prakash et al., 2021b; Sarala Rubi et al., 2022b). Frontiers in Mechanical Engineering 11 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 6.5 Artiﬁcial neural network used for the micro- and high-precision machining of complex shaped items with a range of hardness requiring for precise ANN is a technique developed to simulate the learning process tolerances on dimensions. Additionally, the WEDM process’s of the human brain by creating an artiﬁcial representation of it. feasibility in the next industrial environment has been criticized ANN uses mathematical modeling or computational model to create by the arrival of newer and more exotic materials. Therefore, it is a group of interconnected artiﬁcial neurons to process the necessary to make constant enhancements to the current WEDM information ‘‘based on a connectionist approach to qualities to expand the machining capabilities and raise machining computation’’. ANN model consists of interconnecting neurons, efﬁciency and effectiveness. which ‘‘may share some properties of biological neurons’’. ANN The main aim of the WEDM method is to produce a precise neurons networks represent an artiﬁcial model that simulates the and effective machining operation without affecting machining biological nervous system. ANN structure consist of a group of performance. This is mostly accomplished by comprehending the neurons plays the role of simple processors. Together neurons work relationships that exist between the numerous process-affecting as a non-linear mapping system (Ozcelik et al., 2005). Each neuron elements and selecting the ideal machining condition from weights each connection with the other neurons. The inputs from all among the uncountable potential combinations. Moreover, preceding neurons calculated by using a speciﬁc formula to create substantial use of adaptive monitoring and control systems net input for each neuron and the neuron will generate output which has been made in order to govern WEDM behavior without can be an input to the next neurons or it may represent the model increasing the danger of wire breakages and might lessen the output if this neuron is the output layer (Padhi and Satapathy, 2013). error brought on by the wire’s static deﬂection and ANN architecture layers and number of neurons depends on the vibrating behavior. number of inputs and outputs of the model. Furthermore, it has been stated that a number of optimization Artiﬁcial neural networks are used for solving a variety of techniques based on explicit mathematical models, expert problems, and they are inspired by the biological nervous system. knowledge, or intelligent systems helps to ﬁnd the optimal ANNs are composed of neurons and like the biological nervous process parameters. The WEDM process must be continuously system they can learn; therefore they are trained to ﬁnd solution to a enhanced to remain a viable and cost-effective machining problem (Zhang et al., 2002; Altug et al., 2015; Stalin et al., 2019; operation in the contemporary tool room production Stojanovic et al., 2022). The simplest ANN consists of input layer, environment, given the ongoing trend towards uncontrolled hidden layer and output layer. Each layer has different number machining operations and automation. of neurons. Author contributions 6.6 Genetic algorithm CS: Conceptualization, Data curation, Formal Analysis, The genetic algorithm (GA) method is based on genetics and Investigation, Methodology, Project administration, Resources, natural selection. It is employed to ﬁnd optimal or near-optimal Writing–original draft. UP: Conceptualization, Methodology, solutions to difﬁcult problems. It works on three types of operators, Project administration, Resources, Writing–original draft. SJ: namely, reproduction, crossover, and mutation. The strongest pair Methodology, Project administration, Software, Visualization, was chosen, and mutation was introduced due to the different Writing–review and editing. RC: Funding acquisition, crossovers in the gene pool. The strongest and best among them Methodology, Project administration, Software, Writing–review is chosen as solutions (Manoj et al., 2022; Udaya Prakash and editing. SS: Funding acquisition, Investigation, Methodology, et al., 2023d). Project administration, Writing–original draft. KK: Funding acquisition, Investigation, Methodology, Project administration, Writing–review and editing. SR: Data curation, Formal Analysis, 6.7 Analysis of variances Investigation, Resources, Writing–review and editing. ANOVA is a technique used to determine signiﬁcant factors based on their contribution to process outcomes/results/ Funding performance measures. Factors effects obtained by separating the total outcomes variability. Variability measured by ‘‘calculating the The author(s) declare ﬁnancial support was received for the sum of the squared deviations (SST) from the total mean of the research, authorship, and/or publication of this article. This work process outcomes, the variability of the process parameters (SSF), was supported by the project SP2023/088 supported by the Ministry and the error (SSE)’’ (Jebarose Juliyana et al., 2022b). of Education, Youth and Sports, Czech Republic. 7 Conclusion Conﬂict of interest WEDM is a well-known non-traditional material removal The authors declare that the research was conducted in the technique that can handle the various machining demands put absence of any commercial or ﬁnancial relationships that could be forth by the metal working industries. It has frequently been construed as a potential conﬂict of interest. Frontiers in Mechanical Engineering 12 frontiersin.org Sarala Rubi et al. 10.3389/fmech.2024.1322605 Publisher’s note organizations, or those of the publisher, the editors and the reviewers. 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Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

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Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

Comprehensive review on wire electrical discharge machining: a non-traditional material removal process

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