A soft computing-based analysis of cutting rate and recast layer thickness for AZ31 alloy on WEDM using RSM-MOPSO

Kapil K. Goyal, Neeraj Sharma, Rahul Dev Gupta, Gurpreet Singh, Deepika Rani, Harish Kumar Banga, Raman Kumar, Danil Yurievich Pimenov, Khaled Giasin*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

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In the present research, the AZ31 alloy is machined by wire-cut electric discharge machining (WEDM). The experiments were designed according to the Box-Behnken design (BBD) of response surface methodology (RSM). The input process variables, namely servo feed (SF), pulse on-time (Ton), servo voltage (SV), and pulse off-time (Toff), were planned by BBD, and experiments were performed to investigate the cutting rate (CR) and recast layer thickness (RCL). The analysis of variance (ANOVA) was performed to determine the influence of machining variables on response characteristics. The empirical models developed for CR and RCL were solved using Multi-Objective Particle Swarm Optimization (MOPSO). Pareto optimal front is used for the collective optimization of CR and RCL. The optimal solution suggested by the hybrid approach of RSM-MOPSO is further verified using a confirmation test on the random setting indicated by the hybrid algorithm. It is found that the minimum RCL (6.34 µm) is obtained at SF: 1700; SV: 51 V; Toff: 10.5 µs; and Ton: 0.5 µs. However, maximum CR (3.18 m/min) is predicted at SF: 1900; SV: 40 V; Toff: 7 µs; and Ton: 0.9 µs. The error percentage of ±5.3% between the experimental results and predicted solutions confirms the suitability of the proposed hybrid approach for WEDM of AZ31.
Original languageEnglish
Article number635
Number of pages22
Issue number2
Publication statusPublished - 15 Jan 2022


  • AZ31 alloy
  • hybrid approach
  • Multi-Objective Particle Swarm Optimization (MOPSO)
  • recast layer
  • ; response surface methodology (RSM)
  • wire-cut electric discharge machining (WEDM)


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