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The electric discharge machining (EDM) involves electrons discharged from the electrode and machining progresses due to the removal of the material from the component. This a thermal-based machining process primarily used for hard to machine components with conventional methods. This process is used to make intricate cavities and contours. The fabricated part is the replica of the tool material with high surface finish and good dimensional accuracy. This study aims to evaluate the comprehensive effect of process parameters on electric discharge machining of maraging steel.

Multiple criteria Decision making (MCDM) techniques are used to select the best parameters by comparing several responses to achieve the desired goal. There are different MCDM techniques available for optimization of machining parameters. In the current investigation, multi-objective optimization by data envelopment analysis based ranking (DEAR) approach was used for machining Maraging C300 grade steel.

The Taguchi L9 runs were planned with process parameters such as current (Amp), Tool diameter (mm) and Dielectric pressure (MPa). The effect of process parameters on the responses, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were evaluated. High MRR is found at 15 A current, 14 mm tool diameter and dielectric pressure of 0.2 MPa. Optimum process parameters experiment showed reduced crack density.

An effort was made successfully to enhance the responses using the DEAR method and establish the decision making of selecting the optimal parameters by comparing the results obtained by machining maraging steel C300 grade.