M.J Haddad - Ph.D. Student, Manufacturing Engineering Group, Tarbiat Modares University, Tehran, Iran
A Fadaei Tehrani - Assist. Prof., Manufacturing Engineering Group, Isfahan University of Technology, Isfahan, Iran
A Mohammadi - Lecturer, Education Workshop Center, Isfahan University of Technology, Isfahan, Iran
N Nehzat - Assist. Prof., Manufacturing Engineering Group, Isfahan University of Technology, Isfahan, Iran

In this paper, the effects and optimization of machining parameters on surface roughness (Ra) and roundness in Cylindrical Wire Electrical Discharge Turning (CWEDT) process is investigated. The CWEDT process was developed to generate precise cylindrical forms on hard, difficult to machine materials. A precise, flexible and corrosion resistance underwater rotary spindle was designed and added to a conventional five axis wire EDM machine to enable the generation of free form cylindrical geometries. Ra and roundness are chosen as the machining parameters to verify the process. In addition, power, voltage, pulse off time and spindle rotational speed were adopted for evaluation by Taguchi method. A L9(34) Taguchi standard orthogonal array is chosen for the design of experiments. The level of important of the machining parameters on Ra and roundness are determined by using analysis of variance (ANOVA). The optimum machining parameter combination was obtained by using the analysis of signal to noise (S/N) ratio. The variation of Ra and roundness with machining parameters is mathematically modeled by using regression analysis method. Finally, experimental tests were carried out to identify the effectiveness of this proposed method.

CWEDT, Surface integrity, Statistical analysis