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In recent years, Wire-Electrical Discharge Machining (WEDM) has gained popularity in industry due to its capability to generate complicated shapes in exotic materials, irrespective of their hardness. Conventional machining of Nimonic C-263 super alloy is an extremely difficult and costly process due to its high hardness and tool wear rate. The present research work investigates the influence of the WEDM process parameters on different performance measures during machining of Nimonic C-263 super alloy.Mathematical model for all four important performance measures, namely, cutting rate, surface roughness, spark gap and wire wear ratio, was developed and the responses were used for studying the inter-relationship between performance measures and process parameters. The optimal settings of operating conditions were predicted using desirability function. The effectiveness of multi-cut strategy was also investigated in the paper.

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