Investigating the Effect and Optimization of WEDM Parameters on LM26 Aluminium Alloy Hybrid Composites: An Response Surface Methodology Based Desirability Approach

This study seeks to optimize the Wire Electrical Discharge Machining (WEDM) parameters to improve the machining performance of hybrid MMCs based on LM26 aluminium alloy. The study focuses on the effects of three important WEDM parameters: current, idle time, and energy time. The process was modeled and optimized using Response Surface Methodology (RSM)-based Central Composite Design (CCD) in conjunction with a multi-objective desirability analysis. According to the experimental results, WWR ranged from 0.001 to 0.017, and Kw varied between 0.22468 mm and 0.38063 mm. Energy time and current were the two parameters that significantly affected Kw, while longer idle time reduced WWR because it improved cooling and effectively removed debris. With an Adjusted R² of 0.9605 and a Predicted R² of 0.8620, the analysis of variance validated the model’s dependability. 10.65 µs energy time, 11.904 µs idle time, and 4.15164 Amps current were found to be the ideal machining parameters, which led to an optimized Kw of 0.280582 mm and a minimized WWR of 0.00593563. High prediction accuracy was demonstrated by experimental validation, which revealed low error values for Kw (0.0096) and WWR (0.0423). The results highlight how stable, accurate, and effective machining of LM26-based hybrid MMCs can be accomplished with WEDM settings that are optimized. This supports high-precision applications in sectors where component reliability is crucial by improving dimensional accuracy and tool longevity.