A Mohammadi - Lecturer, Isfahan University of Technology
A Fadaie Tehrani - Assistant professor, Isfahan University of Technology
E Emanian - Researcher in Farakosh Sepahan Co., Isfahan Science & Technology Town
D Karimi - MS student, University of Tarbiat Modares

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 costeffectiveness of the process. Several experiments are conducted to consider effects of power, time off, voltage, servo, wire feed rate, wire tension, and rotational speed (factors) on the MRR (response). A L18 (21×37) Taguchi standard orthogonal array is chosen for the design of experiments. Analysis of variance (ANOVA) as well as regression analysis are performed on experimental data. S/N ratio analysis is employed to find the optimal condition.

TWEDM, Design, Material Removal Rate, Free form, Statistical Analysis