The purpose of this study is to examine the material removal rate in wire electrical discharge machining (WEDM) of AZ91-Mg material and compare the performance of a newly developed molybdenum wire with that of plain brass wire. Experiment was performed for two groups namely group 1 AZ91-Mg material with plain brass wire l and group 2 AZ91-Mg material with molybdenum wire. There are 20 pieces of work in each group. The experimental setup included preparing the workpiece, setting up the WEDM machine, adjusting cutting parameters, measuring MRR (Material removal rate), and analyzing the results. In this procedure, G-power is set to 80%, sample size is determined using the formula α = 0.05 per set, and a sample size of 20 is determined. In this study, MRR is found through initial weight of workpiece (gm) – final weight of workpiece (gm). The obtained data, including MRR values, surface roughness, and dimensional accuracy, were compared to evaluate the effect of wire type on MRR. These results showed that there was a statistically significant difference between the two groups with the p value is 0.000 (p < 0.05). Within the limitations of the study, MRR of AZ91-Mg material with molybdenum wire and plain brass wire is maximal at the same process parameter.

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