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The material removal rate (MRR) and surface roughness (SR) are the key output measures of wire electrical discharge machining (WEDM). In this paper, the influence of several process parameters, such as the discharge current, pulse interval, open-circuit voltage and servo voltage on the MRR and SR of WEDM, were investigated. Experimental data were initially collected based on the Taguchi method of experimental design. Modelling was carried out using regression analysis and the analysis of variance techniques, and mathematical relationships between the parameters and their related outputs were developed and tested. A Tabu search algorithm was then used to minimize a weighted sum of the outputs that represent different measures of machining quality and determine the optimal set of parameters for any combination of the weighting factors. The final results present the optimized MRR and SR of the process and confirm the efficiency and abilities of the model.

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