Gaussian Process Modeling of EDM Performance Using a Taguchi Design

Electrical discharge machining (EDM) is widely used for machining hard and difficult-to-cut materials; however, the complex and nonlinear nature of the process makes the accurate prediction of key performance indicators challenging, particularly when only limited experimental data are available. In this study, a combined Taguchi design and Gaussian process regression (GPR) modeling framework is proposed to predict the surface roughness (Ra), material removal rate (MRR), and overcut (OC) in die-sinking EDM. An L18 Taguchi orthogonal array was employed to efficiently design experiments involving discharge current, pulse duration, and electrode material. GPR models with an automatic relevance determination (ARD) radial basis function kernel were developed to capture nonlinear relationships and varying parameter relevance. Model performance was evaluated using strict leave-one-out cross-validation (LOOCV). The developed GPR models achieved low prediction errors, with RMSE (MAE) values of 0.54 µm (0.41 µm) for Ra, 1.56 mm3/min (1.21 mm3/min) for MRR, and 0.0065 mm (0.0055 mm) for OC, corresponding to approximately 9.8%, 5.4%, and 5.9% of the respective response ranges. These results confirm stable and reliable predictive accuracy within the investigated parameter domain. Based on the validated surrogate models, multi-objective optimization was performed to identify Pareto-optimal process conditions, revealing graphite electrodes as the dominant choice within the feasible operating region. The proposed approach demonstrates that accurate and robust prediction of EDM performance can be achieved even with compact experimental datasets, providing a practical tool for process analysis and optimization.