This research examines the impact of Wire EDM (WEDM) process variables on the responses namely kerf width (KW) and surface roughness (Ra), Tool-steel O1 is considered as workpiece material. The Taguchi design was subjected to a total of (9) experiments. The research was carried out using the Taguchi approach as an optimization method, taking into account the varying parameters of (Pulse Duration, Servo-Feed, and Pulse-off). The findings show that KW and Ra are significantly influenced by (Pulse Duration, Servo-Feed, and Pulse-off). For KW and Ra, the (Servo-Feed) is the most important variable. Minitab version 18 software was used to evaluate the results. The results show that the Servo-Feed is the most prompting factor which affects the surface roughness and kerf width. The better roughness of the machined surface is (4.21) µm can be achieved at conditions (400 mm/min, 40 µs, 30 µs), whereas the smallest value of kerf width is (330.48) µm at ( 400 mm/min, 20 µs, 10 µs) for servo-feed, pulse duration, and pulse off time respectively.

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