Analysis and optimization of sustainable machining of AISI O1 tool steel by the wire-EDM process

Wire electrical discharge machining (wire-EDM) is an energy-intensive process, and its success relies on a correct selection of cutting parameters. It is vital to optimize energy consumption, along with productivity and quality. This experimental study optimized three parameters in wire-EDM: pulse-on time, servo voltage, and voltage concerning machining time, electric power, total energy consumption, surface roughness, and material removal rate. Two different plate thicknesses (15.88 mm and 25.4 mm) were machined. An orthogonal array, signal-to-noise ratio, and means graphs, and an analysis of variance (ANOVA), determine the effects and contribution of cutting parameters on responses. Pulse-on time is the most significant factor for almost all variables, with a percentage of contribution higher than 50%. Multi-objective optimization is conducted to accomplish a concurrent decrease in all variables. A case study is proposed to compute carbon dioxide (CO2) tons and electricity cost in wire-EDM, using cutting parameters from multi-objective optimization and starting values commonly employed to cut that tool steel. A sustainable manufacturing approach reduced 5.91% of the electricity cost and CO2 tons when machining the thin plate, and these responses were diminished by 14.09% for the thicker plate. Therefore, it is possible to enhance the sustainability of the process without decreasing its productivity and quality.

Automated summary

Wire electrical discharge machining is an energy-intensive process that requires correct selection of cutting parameters to optimize energy consumption, productivity, and quality. Experimental study and multi-objective optimization can reduce electricity cost and CO2 emissions, enhancing sustainability without compromising productivity and quality.