Simultaneous optimization of dimensional accuracy and surface roughness for finishing cut of wire-EDMed K460 tool steel

Abstract The aim of this research was to determine an optimal cutting condition of dimensional accuracy and surface roughness for finishing cut of wire-EDMed K460 tool steel. The cutting variables investigated in this study encompassed cutting speed, peak current, and offset distance. Box–Behnken design was employed as the experimental strategy, and multiple response optimization on dimensional accuracy and surface roughness was performed using the desirability function. Results showed that both peak current and offset distance have a significant effect on the dimension of the specimen while peak current alone affects the surface roughness. The optimal cutting condition was at 2 A peak current and 772 μm offset distance. Since neither dimension nor surface roughness was affected by cutting speed, the speed was thus set at the highest of 5.5 mm/min to maximize the production rate. Confirmation tests on the optimal cutting condition were executed by which all cut specimens were shown to be within the specifications.