Measurement of WEDM performance characteristics of aero-engine alloy using RSM-based TLBO algorithm

[Display omitted] •WEDM-cutting performance of advanced aero-engine alloy is measured.•Surface morphology, topography, recast layer, and roughness values are evaluated.•RSM-based TLBO is used for precise estimation of roughness and removal rate.•Pareto optimal solutions are obtained at different weightage. Alloy-706 is a newly introduced exceptional class of turbine wheel alloy for high-performance aero-engine. To precisely measure the WEDM performance of complex aero-engine parts, the RSM-based TLBO algorithm is proposed in the current study. Morphology, topography, recast layer thickness, and roughness parameters of machined surface are studied to examine the surface integrity of aero-engine components. Better surface morphology, smoother topography, low roughness value, and minimum recast layer are observed at low pulse duration, high pulse-off period, and high servo voltage. RSM is used for statistical modeling of removal rate and average roughness. Then, these models are used in TLBO algorithm for individual and multiple performance optimizations. The Pareto optimal solutions are obtained for lower roughness value and highest removal rate. The microscopic investigation represents a considerable number of melted droplets, micro-holes, and craters on the WEDM-cut surface due to high energy discharge pulses followed by improper flushing of molten material.