Statistical analysis of wire electrical discharge turning on material removal rate

The application of wire electrical discharge machining (WEDM) for machining of precise cylindrical forms on hard and difficult-to-machine materials is presented. At first, the design of a precise, flexible and corrosion-resistant rotary spindle submerged is introduced. The spindle has been mounted on a five-axis wire EDM machine to rotate the workpiece in order to generate free form cylindrical geometries. The material removal rate (MRR) is an important indicator of the efficiency and cost-effectiveness of the process. Several experiments are conducted to consider effects of power, time-off, voltage, servo, wire speed, wire tension, and rotational speed (factors) on the MRR (response). An L18 (21 × 37) Taguchi standard orthogonal array is chosen for the design of experiments. Analyses of variance (ANOVA) as well as regression analysis are performed on experimental data. The signal-to-noise (S/N) ratio analysis is employed to find the optimal condition.