Modeling and Multi-objective Optimization of the Wire Electric Discharge Machining Process of 7075 T6 Aluminum

Authors

1 Department of Mechanical Engineering, Birjand University of Technology, Birjand, Iran

2 Department of mechanical engineering, Shahid Montazari Faculty, Technical and Vocational University,

3 Department of Mechanical Engineering,, University of Birjand

4 Department of Mechanical Engineering, Birjand University of Technology

5 Department of Mechanical Engineering, University of Birjand , Birjand, Iran

Abstract

With increasing industrial competition, limited resources, and the need to simultaneously achieve high quality, higher productivity, and reduced manufacturing costs, process optimization has become a key pillar in the development of advanced manufacturing technologies. In this study, multi-objective modeling and optimization of the wire electrical discharge machining (WEDM) process for 7075 aluminum alloy were investigated. Four control parameters, including voltage, current, pulse-on time, and pulse-off time, were examined using a Box–Behnken response surface design, and their effects on surface roughness, material removal rate, and kerf width were evaluated. To model the nonlinear behavior of the process, Gaussian process regression with a Matérn covariance function was employed, and model performance was assessed using five-fold cross-validation. The results indicated satisfactory predictive accuracy, particularly for surface roughness. Subsequently, the problem was formulated as a multi-objective optimization task with the objectives of minimizing surface roughness and kerf width while maximizing material removal rate, and the non-dominated sorting genetic algorithm was used to obtain the Pareto front. The findings revealed an inherent trade-off between surface quality and machining productivity, and an experimental validation test at the selected optimal point confirmed a relative error of less than 7%.

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Journal of Solid and Fluid Mechanics
Volume 16, Issue 4
September and October 2026
Pages 455-471

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