Corner accuracy occurring in wire electrical discharge machining (WEDM) is influenced by machining parameters such as wire vibration, wire lag, and excessive discharge, etc. This study proposed an optimization method which can improve the corner accuracy of the WEDM process. The parameters of pulse-on time (ON), pulse-off time (OFF), open circuit voltage (OV), servo voltage (SV), wire tension (WT), and flushing pressure (WA) were selected to investigate the influences of the major parameters on the machining accuracy in this study. Three different corner angles of 30°, 60°, and 90° were chosen for the verification experiments. The response surface methodology (RSM) was used to analyze and investigate the effect of each parameter on the corner error. After integrating the response surface value and algorithm, an optimization system with a friendly human–machine interface, which has a procedure guiding function, was developed with use of C# language. The system can predict the corner error and also recommend optimal machining parameters for smaller corner error and faster machining speed based on the original machining parameters. Finally, cutting experiments were conducted to verify the proposed system, and the results showed that the proposed method can effectively improve the corner accuracy by 39%, 20%, and 33%.

This study proposes a hybrid optimization method which can help users to find optimal cutting parameters which will provide better efficiency and lower power consumption for a milling process. Empirical models including performance-power consumption characteristic curves of servo motors were built, and an optimization algorithm adopting the empirical models with procedure guiding function was developed. The empirical models were built based on the measurements from planned machining experiments with different combination of machining parameters including spindle speed, feedrate, and chip load, etc. After integrating the models and algorithm, an optimization system with human machine interface, which has procedure guiding function, was developed. The system can recommend optimal machining parameters for a milling process for shorter machining time and lower electricity costs based on the original machining parameters. Finally, cutting experiments were conducted to verify the proposed system, and the results showed that the proposed method can effectively enhance efficiency by 42.06% and save 34.74% in machining costs through reducing machining time and electrical power consumption.