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The purpose of this paper is to examine the performance parameters of WEDM to improve the productivity and material removal rate (MRR) with a high surface finish of high chromium-high carbon dies steel.

The experiments were performed on AGIE CUT 220 CNC WEDM. High chromium-high carbon dies steel (D3) was used in the form of a rectangular plate. The workpiece and the brass wire having diameter ɸ 0.25 mm had linked up with +ve and –ve polarity in the DC power source, respectively. De-ionized water having a conductivity level of 0.6 µs/cm was used as the dielectric medium. The dielectric fluid was flushed from the top and bottom nozzles and material was submerged in the dielectric.

The WEDM process parameters for D3 die steel had optimized by using Grey relational analysis method couples with Taguchi method. The optimum solution has been calculated for MRR, cutting speed (Cs), machining time and surface roughness (SR) (Ra value). A fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, cutting speed (Cs), machining time (M/c time) and SR with respect to changes in input parameters.

The fuzzy model shows the 96.19 percent accuracy between the experimental values and the predicted values.

The optimized parameters by multi-parametric optimization method showed considerable improvement in the process and will facilitate the WEDM, tool and die industries, defense and aerospace industries to improve the productivity with the higher surface finish.

This manuscript represents valid work and the authors have no conflict of interests. The attained optimum outcomes had also been examined through a real experiment and established to be satisfactory.