Prioritization Of Critical Process Parameters In Wire Electrical Discharge Machining Using Analytic Hierarchy Process: A Comprehensive Analysis

Authors

  • Dipak P Kharat Research Scholar, Dept of Mechanical Engg. Prof.Ram Meghe Institute of Technology and Research Badnera –Amravati-444701(MS)
  • Dr.M.P. Nawathe Professor Dept of Mechanical Engg. Prof.Ram Meghe Institute of Technology and Research Badnera –Amravati-444701(MS)
  • Dr.C.R. Patil Professor Dept of Mechanical Engg. Prof.Ram Meghe Institute of Technology and Research Badnera –Amravati-444701(MS)

DOI:

https://doi.org/10.63278/mme.vi.1676

Keywords:

WEDM, AHP, Process Optimization, Multi-Criteria Decision Making, Machining Parameters, Surface Roughness, Material Removal Rate, Dimensional Accuracy.

Abstract

Wire Electrical Discharge Machining (WEDM) is a non-conventional machining process widely employed in aerospace, medical, and automotive industries for cutting electrically conductive materials with intricate geometries. The process performance is governed by multiple interdependent parameters, making optimization a complex challenge. This study employs the Analytic Hierarchy Process (AHP) a structured Multi-Criteria Decision-Making (MCDM) technique to systematically rank critical WEDM parameters based on their influence on surface roughness (Ra), material removal rate (MRR), and dimensional accuracy. Five key parameters i.e Pulse-on Time (TON), Pulse-off Time (TOFF), Wire Feed Rate (WF), Peak Current (IP), and Sensitivity (SEN) were evaluated using pairwise comparisons and eigenvalue-based weighting. Results indicate that Peak Current (IP, 37.4%) and Pulse-on Time (TON, 26.2%) exert dominant influence on process performance, collectively contributing 63.6% of the total influence. The findings align with experimental studies across diverse materials and machining contexts, validating AHP as an effective tool for WEDM optimization. The study provides a structured decision-making framework for industries to prioritize parameter adjustments, thereby reducing trial-and-error approaches and improving machining efficiency and quality outcomes.

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How to Cite

Kharat, Dipak P, Dr.M.P. Nawathe, and Dr.C.R. Patil. 2025. “Prioritization Of Critical Process Parameters In Wire Electrical Discharge Machining Using Analytic Hierarchy Process: A Comprehensive Analysis”. Metallurgical and Materials Engineering, May, 1067-81. https://doi.org/10.63278/mme.vi.1676.

Issue

Vol. 31 No. 5 (2025)

Section

Research

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Copyright (c) 2025 Dipak P Kharat, Dr.M.P. Nawathe, Dr.C.R. Patil

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