Abstract: “Nimonic-263 is a nickel-chromium-cobalt-molybdenum alloy specially meant for use in high temperature and high strength applications. This material is mainly used in gas turbine hot section components. Machining of these high strength materials is a challenging task now a days. Wire cut electrical discharge machining is one of the advanced machining processes and can be used to machine any material, which can electrically conduct, irrespective of its hardness. Selection of process parameters plays a vital role to yield the desired level of performance. An attempt has been made in this work to investigate the behavior of WEDM process while machining Nimonic-263. Response surface methodology has been used for the experimental plan. The influence of process parameters such as pulse on time, pulse off time, peak current and servo voltage on response parameters such as material removal rate and surface roughness has been studied in this work. Mathematical models are developed to predict thes”

Keywords: Nimonic-263, EDM, Optimization, RSM, Differential Evolution