Investigating and Multi-Objective Optimizing WEDM Parameters for Al6061/Mg/MoS2 Composites Using BBD and NSGA-II

This study aims to optimize the Wire Electrical Discharge Machining (EDM) process parameters for aluminum 6061 alloy reinforced with Mg and MoS2 using the Box–Behnken (BBD) design and the non-dominated sorting genetic (NSGA-II) algorithm. The objective is to enhance the machining efficiency and quality of the composite material. The Box–Behnken (BBD) design was utilized to design a set of experiments with varying levels of process parameters, comprising pulse-on time, servo volt, and current. The material removal rate and surface roughness were considered as machining responses for optimization. These responses were measured and used to develop a mathematical model. The NSGA-II, a multi-objective optimization algorithm, was then applied to search for the optimal combination of process parameters that simultaneously maximizes the material removal rate and minimizes the electrode wear rate and surface roughness. The algorithm generated and evolved a set of Pareto-optimal solutions, providing a trade-off between conflicting objectives. The results of the optimization process were analyzed to identify the optimal process parameters that lead to improved machining performance. The study revealed optimal Wire Electrical Discharge Machining (WEDM) parameters for Al6061/Mg/MoS2 composites using NSGA-II. The optimized parameters, including a pulse-on time (Ton) of 105 µs, servo voltage (SV) of 35 V, and peak current (PC) of 31 A, resulted in a Material Removal Rate (MRR) of 7.51 mm3/min and a surface roughness (SR) of 1.97 µm. This represents a 15% improvement in the MRR and a 20% reduction in the SR compared to non-optimized settings, demonstrating the efficiency of the BBD-NSGA-II approach.