Application of AI and RSM to Optimize WEDM Process Parameters on D4 Steel

This electronic When precision is required, WEDM is a conductive material machining technology that is widely used. The rough cutting operation in WEDM is regarded tough because precision work demands the use of numerous machining performance measurements, such as metal removal rate (MRR), surface finish (SF), and cutting width (kerfs).According toResponse Surface Methodology, discharge current, pulse frequency, wire-speed, wire tension, and dielectric flow are all key machining characteristics that influence performance metrics (RSM). Each performance metric's best set of parameters has been discovered to be different. This study uses nonlinear regression analysis to stabilize the relationship between control variables and response variables like MRR, SF, and kerf, resulting in a valid mathematical model. Little research has been done to establish the ideal quantity of machining parameters for the best machiningquality in tough machining materials such as hot die steel D4 according to the literature review. Hot die steel D4 is widely utilized in applications such as hot work forging, extrusion, punching tools, mandrels, mechanical press forging dies, plastic molds and die casting dies, aviation landing gears, helicopter rotor blades, and shafts, and others. Wire electrical discharge machining is challenging to obtain consistent quality because the process parameters are difficult to maintain. The most challenging problems for researchers and engineers to address are those listed above. Manufacturers strive to find control elements to increase machining quality based on their operational experiences, manuals,or failed attempts. Electronic Process Tools Limited's wire cut EDM was used to machine D4 hot die steel specifically for this application (Elektra Spirit cut 734).