Wire electric discharge machining is a non-conventional machining wherein the quality and cost of machining are influenced by the process parameters. This investigation focuses on finding the optimal level of process parameters, which is for better surface finish, material removal rate and lower wire consumption for machining stainless steel-316 using the grey–fuzzy algorithm. Grey relational technique is applied to find the grey coefficient of each performance, and fuzzy evaluates the multiple performance characteristics index according to the grey relational coefficient of each response. Response surface methodology and the analysis of variance were used for modelling and analysis of responses to predict and find the influence of machining parameters and their proportion of contribution on the individual and overall responses. The measured values from confirmation experiments were compared with the predicted values, which indicate that the proposed models can be effectively used to predict the responses in the wire electrical discharge machining of AISI stainless steel-316. It is found that servo gap set voltage is the most influential factor for this particular steel followed by pulse off time, pulse on time and wire feed rate.
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