ABSTRACT
In this investigation, an experimental study in cylindrical wire EDM machining parameters
followed by statistical analysis is presented for cross-feed turning process.
At first, the features of rotary spindle are presented. The spindle has been mounted
on a conventional four-axis wire EDM machine to provide the workpiece rotation in
order to generate free form cylindrical geometries. Several experiments are conducted
to investigate the influence of six design factors: the depth of cut (a), gab (g),
spindle rotational speed (n), pulse time-on (
), wire feed speed () and interval
time (
) on the material removal rate (MRR) and surface roughness (Ra) as an
indicators of the efficiency and cost-effectiveness of the process. Stainless steel
k316 is one of the difficult-to-machine material, was used in this study. An L18
(×
) Taguchi standard orthogonal array is chosen for the design of experiments
(DOE) due to the number of factors and their levels in the investigation. Mini tab
Software version 16 was used to determine the main effects of the process parameters.
Analysis of variance (ANOVA) was performed to find the dependent variables
that effect the machining characteristics, Regression analysis is performed to find out
the relationship between the different factors and responses, S/N ratio analysis is
used to establish the optimum condition.