The present study focuses on optimization of operating parameters in wire electric discharge machining of AA2024 aluminium alloy reinforced with lithium and silicon nitride particles. Aluminium composite was produced through the two-step stir casting route with the combination of 2% lithium and 10% silicon nitride reinforcements. Experiments were performed using the Taguchi design of experiments to optimize the selected input parameters such as pulse on time, pulse off time, current and wire feed for the response parameter, material removal rate, and surface roughness. An ANOVA-based regression equation with genetic algorithm was used to optimize the input variables. The gray relational grade was also performed to optimize multiple performance characteristics. Taguchi-based optimization analysis results in wire feed as the domination factor for material removal rate and surface roughness. Increased wire feed increases the material removal rate with good surface finish as confirmed from gray relational grade analysis. Regression equation generated results with minimum error (<2%) proving the accuracy of the investigation. A genetic algorithm-based study also confirms the analysis of Taguchi and gray relational grade. The wire feed rate at 3 m/min and pulse on time of 120 microseconds were found to be similar for material removal rate and surface finish. Current at 50 A increases the material removal rate and current at 30 A results in good surface finish.

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