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 variance (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 (CO₂) 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 CO₂ 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.

线切割加工（wire-EDM）是一项耗能大的过程，其成功取决于正确选择切削参数。优化能源消耗以及生产率和质量至关重要。该实验研究优化了电火花线切割机中的三个参数：脉冲接通时间，伺服电压以及与加工时间，电功率，总能耗，表面粗糙度和材料去除率有关的电压。加工了两种不同的板厚度（15.88 mm和25.4 mm）。正交阵列，信噪比和均值图以及方差分析（ANOVA）确定了切削参数对响应的影响和贡献。脉冲接通时间是几乎所有变量的最重要因素，其贡献百分比高于50％。进行多目标优化以同时减少所有变量。提出了一个案例研究来计算二氧化碳（CO₂）使用多目标优化中的切削参数和通常用于切削该工具钢的起始值，得出电火花线切割机的吨数和电费。可持续的制造方法在加工薄板时减少了5.91％的电力成本和CO ₂吨，对于较厚的板，这些响应减少了14.09％。因此，可以在不降低其生产率和质量的情况下提高该过程的可持续性。