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 vari-ance(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(CO_(2))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 CO_(2)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.