The magnesium alloy AZ31 is frequently utilized in aerospace and medical industries. Since its density is similar to human bone, it is widely used in medical science and other related areas. In this study, 10 mm thick workpieces of AZ31 were heat treated in a muffle furnace at 400 °C for 3 and 5 hours respectively after which it was normalized to room temperature. Experiments were conducted based on the Box Behnken Design (BBD) approach of Response Surface Methodology (RSM) and second order regression model was developed based on the experimental data to find the correlation of pulse-on time, pulse-off time, and current with output parameters i.e., cutting velocity (CV) and surface roughness (SR). Parametric analysis using response surface plots reveals that CV continuously decreases when pulse on time (Ton) increases whereas increase of current (I) led to continuous rise of CV. WEDM (wire electrical discharge machine) of magnesium alloy yields better surface finish at lower value of both Ton and Toff (pulse off time).

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