OBRABOTKAMETALLOV Vol. 27 No. 2 2025 technology as its delta values were the lowest at either 0.774 for S/N data or 0.269 for raw data. The ANOVA analysis confirmed that the contribution of the pulse-off time to the utility function performance was minimal (2.59 %), while its P-value (0.164) was high, proving statistically insignificant. The study found that ECW level 4219 in combination with Ig level 16, Ton level 38, Vg level 40 and Toff level 5 resulted in maximum MRR, SR and TWR results. Decreasing Vg and Toff values improved spark stability as well as machining efficiency, but increasing Ig and Ton rates resulted in improved material removal. High correlation existed between the input parameters and the utility function as shown by R² = 93.3 % and adjusted R² = 89.7 % in the statistical model. The model successfully predicts the response parameters as its residual error remains low at 6.656 %. Verification tests confirmed the most suitable process conditions resulting in an average MRR rate of 8.852 mm³/min along with SR values of 2.818 µm and TWR readings of 0.148 mm³/min. The experimental results fell within the specified 95 % confidence interval, confirming the robust and stable nature of the optimized processing parameters. The optimized process achieves excellent MRR levels along with minimal SR and TWR, making it suitable for precision manufacturing operations. References 1. Sharma P., Kishore K., Sinha M.K., Singh V. Electrical discharge machining of nickel-based superalloys: a comprehensive review. International Journal of Materials Engineering Innovation, 2022, vol. 13 (3), pp. 157–190. DOI: 10.1504/IJMATEI.2022.125119. 2. Qudeiri J.E.A., Zaiout A., Mourad A.H.I., Abidi M.H., Elkaseer A. Principles and characteristics of different EDM processes in machining tool and die steels. Applied Sciences, 2020, vol. 10 (6), p. 2082. DOI: 10.3390/ app10062082. 3. Philip J.T., Mathew J., Kuriachen B. Transition from EDM to PMEDM–impact of suspended particulates in the dielectric on Ti6Al4V and other distinct material surfaces: a review. Journal of Manufacturing Processes, 2021, vol. 64, pp. 1105–1142. DOI: 10.1016/j.jmapro.2021.01.056. 4. Slătineanu L., Dodun O., Coteaţă M., Nagîţ G., Băncescu I.B., Hriţuc A. Wire electrical discharge machining – a review. Machines, 2020, vol. 8 (4), p. 69. DOI: 10.3390/machines8040069. 5. Kamenskikh A.A., Muratov K.R., Shlykov E.S., Sidhu S.S., Mahajan A., Kuznetsova Y.S., Ablyaz T.R. Recent trends and developments in the electrical discharge machining industry: a review. Journal of Manufacturing and Materials Processing, 2023, vol. 7 (6), p. 204. DOI: 10.3390/jmmp7060204. 6. Gugulothu B., Aravindan N., Widjaja G., Lakshmanan S.A., Suresh M. Electrical discharge machining parameters and dielectric fluid: a review. Handbook of Research on Advanced Functional Materials for Orthopedic Applications, 2023, vol. 137–147. DOI: 10.4018/978-1-6684-7412-9.ch008. 7. Shastri R.K., Mohanty C.P., Dash S., Gopal K.M.P., Annamalai A.R., Jen C.P. Reviewing performance measures of the die-sinking electrical discharge machining process: challenges and future scopes. Nanomaterials, 2022, vol. 12 (3), p. 384. DOI: 10.3390/nano12030384. 8. Goyal A., Pandey A., Rahman H.U. Present and future prospective of shape memory alloys during machining by EDM/wire EDM process: a review. Sādhanā, 2022, vol. 47 (4), p. 217. DOI: 10.1007/s12046-022-01999-9. 9. Jatti V.S. Multi-characteristics optimization in EDM of NiTi alloy, NiCu alloy and BeCu alloy using Taguchi’s approach and utility concept. Alexandria Engineering Journal, 2018, vol. 57 (4), pp. 2807–2817. DOI: 10.1016/j. aej.2017.11.004. 10. Bahgat M.M., Shash A.Y., Abd-Rabou M., El-Mahallawi I.S. Effects of process parameters on the machining process in die-sinking EDM of alloyed tool steel. Engineering Design Applications III: Structures, Materials and Processes. Springer, 2020, pp. 215–233. DOI: 10.1007/978-3-030-39062-4_19. 11. Harane P.P., Unune D.R., Ahmed R., Wojciechowski S. Multi-objective optimization for electric discharge drilling of waspaloy: a comparative analysis of NSGA-II, MOGA, MOGWO, and MOPSO. Alexandria Engineering Journal, 2024, vol. 99, pp. 1–16. DOI: 10.1016/j.aej.2024.04.049. 12. Liao Z., la Monaca A., Murray J., Speidel A., Ushmaev D., Clare A., Axinte D., M’Saoubi R. Surface integrity in metal machining – Part I: Fundamentals of surface characteristics and formation mechanisms. International Journal of Machine Tools and Manufacture, 2021, vol. 162, p. 103687. DOI: 10.1016/j.ijmachtools.2020.103687. 13. Ishfaq K., Farooq M.U., Pruncu C.I. Reducing the geometrical machining errors incurred during die repair and maintenance through electric discharge machining (EDM). The International Journal of Advanced Manufacturing Technology, 2021, vol. 117 (9), pp. 3153–3168. DOI: 10.1007/s00170-021-07846-1.
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