International Journal on Interactive Design and Manufacturing (IJIDeM) https://doi.org/10.1007/s12008-022-01120-8 ORIGINAL PAPER Statistical analysis of process parameters and multi-objective optimization in wire electrical discharge machining of Al 7075 using weight-based constrained algorithm Kingshuk Mandal 1 · Mukandar Sekh 2 · Dipankar Bose 3 · Souren Mitra 1 · Soumya Sarkar 1 Received: 26 September 2022 / Accepted: 12 November 2022 © The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2022 Abstract In the present work, the influence of four significant wire electrical discharge machining (WEDM) parameters, such as pulse duration (T on ), pulse interval (T off ), servo voltage (S v ) and wire tension (W t ) has been studied on cutting velocity (V c ), diagonal dimensional deviation (D v ) and surface roughness (R a ). Signal-to-noise ratio and analysis of variance are used to analyse the effects of four cutting parameters. An entropy weight method is used to determine the objective weights. An integrated weight-based multi-constrained optimization technique is employed to find the optimal solutions for multiple responses. Optimal solutions show that diagonal dimension deviation (D v ) ranges from 0.128 to 0.241 mm and surface roughness (Ra) ranges from 1.058 to 3.457 m for a wide range of cutting velocity (V c ). It is also found that the weight-based Pareto results are improved by 10.5% (for cutting velocity) 28.3% (for dimensional accuracy) and 13.7% (for surface finish) compared to the general Pareto results. Additionally, an important aspect, radial overcut (δ) is measured to predict the linear error present in the workpiece. Finally, CCI and SEM analyses have been carried out to evaluate the surface characteristics of the machined surface. It is evident from the machined surface that the surface is full of small craters, micro-holes, re-solidified materials and recast globules. Keyword WEDM · Al 7075 · EWM · Diagonal dimensional deviation · Radial overcut 1 Introduction Due to the advancement of technology, conventional mate- rials are being gradually replaced by advanced alloys. In the last decade of their first introduction, high conductive materials, especially aluminium alloys, are at the forefront of engineering materials. Recently, several researchers have focused on them because of their distinctive and attractive qualities [1–5]. Al 7075 is a new generation light metal alloy. It becomes extensively important in present day production industries due to its high capability to resist temperature and stress corrosion cracking [6]. Additionally, it is also known as B Kingshuk Mandal mandal.kingshuk1@gmail.com 1 Production Engineering Department, Jadavpur University, Kolkata 700032, India 2 Mechanical Engineering Department, Aliah University, Kolkata 700160, India 3 Mechanical Engineering Department, NITTTR-Kolkata, Kolkata 700106, India an advanced alloy that widely used in different manufactur- ing industry to make intricate shapes with desired accuracy [7]. Initially, it was considered as an alternative solution to iron and titanium alloy for high temperature applications [8–10]. Later on, it becomes non-dominated in structural applications and the aviation industry [11]. The major appli- cations of this alloy are in turbine industries, heat exchangers, armour, automobile engine cylinders and chemical indus- tries etc. [12, 13]. The material has outstanding mechanical properties. Therefore, machining the material is difficult with traditional techniques [14]. Wire electro discharge machin- ing (WEDM) is a potential solution to effectively machine this material. It is an economical process extensively used in manufacturing industries [15, 16]. In WEDM, material removal takes place by a series of isolated sparks between the tool electrode (wire) and the workpiece submerged in a liq- uid dielectric medium. Initially, electrical discharge energy is converted into thermal energy to melt and vaporized minute amounts of material, which are then propelled and waved out by the external flow of dielectric [17–19]. This dielectric liquid is also used as a coolant to defeat the heat developed 123