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To manufacture quality products at lowest cost in industries, optimization is an effective technique which can be applied to find out the best manufacturing conditions. The objective of this research work is to examine the effect of control factors and to choose the correct settings of these factors to maximize MRR and minimize surface roughness and overcut while WEDM of Inconel-625. The control factors chosen for the study are pulse on time, pulse off time, servo voltage, peak current, wire feed rate and wire tension. Experiments were planned as per Taguchi’s L27 orthogonal design under diverse cutting conditions of control factors. Data envelopment analysis based ranking technique (DEAR) was employed for multi-quality characteristic optimization. The optimal values of control factors was found as pulse on time 118 μs, pulse of time 41μs, servo voltage 30 volts, peak current 230 Amp, wire feed rate 1 m/min and wire tension 5 Gram. From the outcomes of the ANOVA, Pulse-on time was found to be the major significant factor affecting the quality characteristics.

Multi-quality characteristics optimization of WEDM for IN-625 by applying Taguchi DEAR technique