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Wire electrical discharge machining process is a promised advanced material removal process used for manufacturing components with intricate profiles and shapes. AISI 304 is a most common Cr-Ni stainless steel alloy is less expensive and used in the fields of medical, aerospace and food processing because of it’s resistance with respect to corrosion, rust, acids, etc. The present work investigates the effects of Wire EDM process parameters voltage,pulse duration (i.e. pulse on time & pulse off time), and wire feed on the response parameters such as surface roughness (Ra), kerf width(K) and material removal rate (MRR) during machining of AISI 304 steel. Experimentation was planned as per Box-Behnken design (Four factors & three levels) of Response Surface Methodology. Analysis of variance is used to point out most influencing factors on responses.From the experiments exploration, it is found that pulse on time showing positive impact on both material removal rate and Kerf width. A peak voltage with short pulse on time creates minimum surface roughness. Microstructural changes on the machined surface has also been discussed with the aid of Scanning Electron Microscope images.
