A New Approach in Surface Roughness and Roundness Improvement in Wire Electrical Discharge Turning Based on Statistical Analyses

In this paper, the effects and optimization of machining parameters on surface roughness and roundness in turning by wire EDM process are investigated. Surface roughness and roundness, were chosen, as the machining parameters to verify the process. In addition, power, time-off, voltage, servo, wire speed, wire tension and rotational speed were adopted for evaluation by Taguchi method. A L₁₈ (2¹ × 3⁷) Taguchi standard orthogonal array is chosen for the design of experiments. The level of importance of the machining parameters on the surface roughness and roundness is determined by using analysis of variance (ANOVA). The optimum machining parameters combination was obtained by using the analysis of signal-to-noise (S/N) ratio. The variation of surface roughness and roundness with machining parameters is mathematically modeled by using regression analysis method. Finally, experimentation was carried out to identify the effectiveness of the proposed method. A good improvement was obtained.