Efficiency Optimization of the Electroerosive Process in µ-WEDM of Steel MS1 Sintered Using DMLS Technology

Although the application of mathematical optimization methods for controlling machining processes has been the subject of much research, the situation is different for µ-WEDM. This fact has prompted us to fill the gap in this field in conjunction with investigating µ-WEDM’s very low productivity and overall process efficiency, since the current trend is oriented towards achieving high quality of the machined area at a high manufacturing productivity. This paper discusses in detail the application of non-linear programming (NLP) methods using MATLAB to maximize the process performance of µ-WEDM maraging steel MS1 sintered using direct metal laser sintering (DMLS) technology. The novelty of the solution lies mainly in the selection of efficient approaches to determine the optimization maximum on the basis of a solution strategy based on multi-factor analysis. The main contribution of this paper is the obtained mathematical-statistical computational (MSC) model for predicting high productivity and quality of the machined area with respect to the the optimal efficiency of the electrical discharge process in the µ-WEDM of maraging steel MS1 material. During the experimental research and subsequent statistical processing of the measured data, a local maximum of 0.159 mm3·min−1 for the MRR parameter and a local minimum of 1.051 µm for the Rz parameter were identified simultaneously during µ-WEDM maraging steel MS1, which was in the range of the predicted optimal settings of the main technological parameters (MTP).