International Journal of Advanced Technology and Engineering Exploration ISSN (Print): 2394-5443    ISSN (Online): 2394-7454 Volume-13 Issue-139 June-2026
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Integrated PSI–pareto front-based multi-objective optimisation of WEDM parameters for SKD61 tool steel

Huynh Thanh Thuong1, Cao Hoang Tien1 and Nguyen Dinh Tu2

Faculty of Mechanical Engineering,Can Tho University, 3/2 Street, Ninh Kieu Ward,Can Tho City,Vietnam1
Faculty of Mechanical Engineering,Can Tho University of Technology, Nguyen Van Cu Street, Cai Khe Ward,Can Tho City,Vietnam2
Corresponding Author : Huynh Thanh Thuong

Recieved : 18-March-2026; Revised : 15-June-2026; Accepted : 18-June-2026

Abstract

Wire electrical discharge machining (WEDM) of tool steels involves a persistent trade-off between machining quality and productivity, as discharge energy conditions simultaneously influence crater formation and material removal behaviour. This study proposes an integrated multi-objective optimisation framework for WEDM of SKD61 tool steel by combining the Taguchi experimental design, analysis of variance (ANOVA), preference selection index (PSI)-based ranking, and Pareto front analysis. The effects of pulse-on time (T-on), pulse-off time (T-off), servo voltage (SV), and wire feed rate (WFR) on surface roughness (Ra) and material removal rate (MRR) were investigated using a Taguchi L27 experimental design. ANOVA results revealed that SV and T-on were the most influential factors affecting Ra, whereas T-on and T-off predominantly governed MRR. The PSI-based optimisation identified the optimal machining parameters as T-on = 2 µs, T-off = 28 µs, SV = 50 V, and WFR = 8 mm/min, yielding the highest PSI value of 0.8337. Pareto front analysis further illustrated the trade-off relationship between Ra and MRR, while comparative and sensitivity analyses using PSI, grey relational analysis (GRA), and the technique for order preference by similarity to ideal solution (TOPSIS) demonstrated stable optimisation performance under varying weighting conditions. Furthermore, confirmation experiments and external validation using six previously unseen parameter combinations showed good agreement with the optimisation and prediction results within the investigated machining range, thereby supporting the practical applicability of the proposed framework. Overall, the integrated PSI–Pareto approach offers an interpretable, robust, and practically applicable strategy for the multi-objective optimisation of WEDM processes within the investigated machining domain.

Keywords

Wire electrical discharge machining (WEDM), SKD61 tool steel, Multi-objective optimization, Preference selection index (PSI), Pareto front analysis, Surface roughness and material removal rate.

Cite this article

Thuong HT, Tien CH, Tu ND. Integrated PSI–pareto front-based multi-objective optimisation of WEDM parameters for SKD61 tool steel. International Journal of Advanced Technology and Engineering Exploration. 2026;13(139):934-954. DOI : 10.19101/IJATEE.2026.131340306

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