This paper presents the experimental investigation to optimize the WEDM parameters for the effective machining of Nimonic-80A alloy using RSM technique. To determine the optimum machining parameters of WEDM affecting the machining performance of Material removal rate and Surface roughness, the RSM technique is used. The machining results were obtained by variation of input peak current ranging from 50 to 150 Amp, gap voltage ranging from 10 to 80 Volts, duty cycle ranging from 10 to 100μs, and wire speed from 4 to 10mm/min. Regression equations and models are developed using the Anova analysis for determining the significant machining parameters affecting the output responses. The multi response optimizations using the desirability function for MRR and SR for machining of Nimonic-80A Alloy by WEDM is I_P 63Amp, Gv 80 Volts, DS 77μs, and WS 4 mm/min of wire electrode. The SEM analysis of machining samples at high and low level of parameters was done. There is a significant variation in the crater size of the two samples; at high value deep overlapping craters were created while at low levels craters are small with surface appearing smoother.
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