Wire Electrical-Discharge-Machining (WEDM) is a well-known unconventional machining process to produce intricate shapes. However, obtaining a satisfactory WEDM cutting performance is indeed a challenging task during precision cutting. Hence, this investigation aims to attempt a favorable machining parameter setting in order to corner-cutting during WEDM for In-718. Here, machining performance characteristics have been considered based on corner deviation (CD) along with Material Removal Rate (MRR) and surface roughness (SR). Taguchi’s experiment design technique (L₁₆) has been considered to run the experiments. The controllable process parameters are considered as Spark-on-time (S_on), flushing-pressure (F_p), wire-tension (T_w), and discharge-current (I_d). The aforesaid machining performance characteristics have been achieved through the two most popular wire electrodes, i.e., Zinc-coated brass electrode (Zn-BE) and Brass Wire Electrode (BWE), and compared the results. The comparison of performances by the wire electrodes on CD, MRR, and SR varied from 0.0286 mm to 0.0844 mm, 0.0045 g/min to 0.0214 g/min and 3.12 µm to 4.80 µm for BWE and 0.0218 mm to 0.0783 mm, 0.0090 g/min to 0.0342 g/min and 2.58 µm to 4.40 µm for Zn-BE respectively. However, machining with Zn-WE yields reduced CD, SR, and increased MRR value and shows less defect on the WEDMed surfaces than its counterpart. The present study developed the mathematical model based on non-linear regression for correlating the machining parameters with the machining responses. The next step of this study is that a unique optimization strategy, namely grey relation analysis (GRA) integrated with Teaching Learning-Based Optimization (TLBO), has been implemented for achieving optimal parametric setting. The satisfactory machining setting obtained from GRA-TLBO has been compared with GRA-JAYA and GRA-genetic algorithm (GA). The proposed methodology appears more fruitful in terms of computational time and effort.

线材放电加工 (WEDM) 是一种众所周知的非常规加工工艺，可生产复杂的形状。然而，在精密切割过程中，获得令人满意的 WEDM 切割性能确实是一项具有挑战性的任务。因此，本研究旨在尝试一种有利的加工参数设置，以便在 In-718 的 WEDM 过程中进行角切割。在这里，加工性能特征已根据转角偏差 (CD) 以及材料去除率 (MRR) 和表面粗糙度 (SR) 进行了考虑。田口的实验设计技术 (L ₁₆ ) 已被考虑用于运行实验。可控工艺参数被认为是火花时间 (S _on )、冲洗压力 (F _p )、线张力 (T _w) 和放电电流 ( _Id）。上述加工性能特征已经通过两种最流行的线电极，即镀锌黄铜电极（Zn-BE）和黄铜线电极（BWE）实现，并比较了结果。线电极在 CD、MRR 和 SR 上的性能比较从 0.0286 mm 到 0.0844 mm、0.0045 g/min 到 0.0214 g/min 和 3.12 µm 到 4.80 µm（BWE）和 0.0218 mm 到 0.07803 mm、0 Zn-BE 分别为 min 至 0.0342 g/min 和 2.58 µm 至 4.40 µm。然而，使用 Zn-WE 进行加工会降低 CD、SR 和增加 MRR 值，并且在 WEDMed 表面上显示出比其对应物更少的缺陷。本研究开发了基于非线性回归的数学模型，用于将加工参数与加工响应相关联。这项研究的下一步是一个独特的优化策略，即灰色关系分析（GRA）与基于教学的优化（TLBO）相结合，已被实施以实现最佳参数设置。从 GRA-TLBO 获得的令人满意的加工设置已经与 GRA-JAYA 和 GRA-遗传算法 (GA) 进行了比较。所提出的方法在计算时间和工作量方面似乎更有成效。