The Micro wire electrical discharge machining (Micro wire-EDM) process is a modern machining process with various applications in manufacturing micro-parts. The recast layer remaining on the machined surfaces is an inevitable complication of this process. This layer can subsequently affect the machined parts performance. To optimize the recast layer in the micro wire-EDM of the molybdenum microparts, effect of the process parameters on the distribution amplitude of the recast layer was investigated using the Taguchi method. The obtained results showed that the optimal levels of the micro wire-EDM process parameters for achieving the optimal distribution amplitude of the recast layer are as follows: spark pulse-on time of 0.2 μs, cutting speed of 7 mm/min, process voltage of 17 V, and wire tension of 0.45 kg. Also the importance order of the effect of the process parameters on the distribution amplitude of recast layer is as follows: spark pulse-on time, process voltage, cutting speed, and wire tension.
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