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In this paper, wire electrical discharge machining of D3 tool steel is studied. Influence of pulse-on time, pulse-off time, peak current and wire speed are investigated for MRR, dimensional deviation, gap current and machining time, during intricate machining of D3 tool steel. Taguchi method is used for single characteristics optimization and to optimize all four process parameters simultaneously, Grey relational analysis (GRA) is employed along with Taguchi method. Through GRA, grey relational grade is used as a performance index to determine the optimal setting of process parameters for multiobjective characteristics. Analysis of variance (ANOVA) shows that the peak current is the most significant parameters affecting on multi-objective characteristics. Confirmatory results, proves the potential of GRA to optimize process parameters successfully for multi-objective characteristics

Multi-objective optimization in WEDM of D3 tool steel using integrated approach of Taguchi method & Grey relational analysis