Optimization of WEDM Process Parameters for Machining of Friction-Stir-Welded 5754 Aluminum Alloy Using Box–Behnken Design of RSM

In the present study, the effect of wire electrical discharge machining (WEDM) process parameters such a pulse on time, pulse off time and peak current on the machining characteristics such as material removal rate, kerf width, and surface roughness during WEDM of friction-stir-welded 5754 aluminum alloy was investigated. Machining experiments were carried out according to the Box–Behnken design (BBD) of the response surface methodology. Analysis of variance was employed to estimate the significance of WEDM process parameters. The optimization of individual and multiple responses was performed using the desirability analysis to achieve the higher material removal rate, minimum kerf width, and minimum surface roughness. The results indicated that the use of BBD can reduce the number of experiments required for optimizing WEDM process parameters. The confirmation experiment was performed at optimum processes parameters where the predicted values of the response were compared with those of experimental values and a close agreement between these values was found.