1Advanced Manufacturing Centre (AMC), Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia 2Department of Mechanical Engineering, Politeknik Muadzam Shah, 26700 Muadzam Shah, Pahang, Malaysia
Received: January 17, 2021 Accepted: July 7, 2021 Publication Date: August 16, 2021
Copyright The Author(s). This is an open access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are cited.
In this study, surface roughness of material Ti-6Al-4V that is the micro-cylindrical workpieces is analyze involving the wire electrical discharge turning (WEDT). The effects of pulse intensity, voltage, wire tension, and rotational spindle speed are investigate and optimize using the response surface methodology (RSM). Based on the results, the surface of the machined workpieces deteriorates according to the violent energy density generate by a high pulse intensity and voltage along with a low electrode wire tension and spindle speed. The optimal surface roughness obtains experimentally through the desirability approach is 4.0143 μm with a relative error at 5.9% compared to prediction.
 D. Huo, W. Chen, X. Teng, C. Lin, and K. Yang, (2017) “Modeling the influence of tool deflection on cutting force and surface generation in micro-milling" Micromachines 8(6): 188. DOI: 10.3390/mi8060188.
 M. Firdauz, R. Izamshah, M. Akmal, M. Kasim, and S. Ding, (2020) “Statistical evaluation on the effects of rotation speed in hybrid micro wire electrical discharge turning" Journal of Advanced Manufacturing Technology (JAMT) 14(2 (2)): 123–135.
 Y. Sun and Y. Gong, (2018) “Experimental study on fabricating spirals microelectrode and micro-cutting tools by low speed wire electrical discharge turning" Journal of Materials Processing Technology 258(1): 271–285.DOI: 10.1016/j.jmatprotec.2018.04.007.
 M. Akmal, R. Izamshah, M. Kasim, M. Hadzley, M. Amran, and A. Ramli. “Development of a rotary axis mechanism for wire EDM turning (WEDT)”. In: Proceedings of Mechanical Engineering Research Day. 2016. Centre for Advanced Research on Energy, 2016, 62–63.
 M. Akmal, R. Izamshah, and M. Kasim, (2018) “Cutting capabilities for macro-micro cylindrical shapes component by wire electrical discharge turning (WEDT)" Proceedings of Innovative Research and Industrial Dialogue 18 1(0): 178–179.
 S. Mondal and D. Bose. “Investigation on forming of small cylindrical geometries in electrolytic tough pitch copper by wire electrical discharge turning process”. In: Proceeding of 10th International Conference on Precision, Meso, Micro and Nano Engineering (COPEN 10). Chennai, 2017, 2–5.
 M. Vignesh and R. Ramanujam, (2019) “Machining of Ti-6Al-4V using diffusion annealed zinc-coated brass wire in WEDHT" Journal of the Brazilian Society of Mechanical Sciences and Engineering 41(9): 359.DOI: 10.1007/s40430-019-1860-2.
 Y. Sun, Y. Gong, Y. Liu, M. Cai, X. Ma, and P. Li, (2018) “Experimental investigation on effects of machining parameters on the performance of Ti-6Al-4V micro rotary parts fabricated by LS-WEDT" Archives of Civil and Mechanical Engineering 18(2): 385–400. DOI: 10.1016/j.acme.2017.09.006.
 M. Jaafar, M. Salleh, R. Izamshah, M. Hassan, S. Sundi, M. Hafiz, and M. Kasim, (2019) “Influence on thrust force and delamination for one shot drilling of carbon fibre reinforced plastic (CFRP)" International Journal of Mechanical & Mechatronics Engineering 19(1): 43–56.
 G. Tigere, U. M. Iqbal, and S. Vignesh, (2019) “Comparative study of different coolants in end milling of OHNS using minimum quantity lubrication technique" Journal of Applied Science and Engineering 22(1):93–101. DOI: 10.6180/jase.201903_22(1).0010.
 A. Kojima, W. Natsu, and M. Kunieda, (2008) “Spectroscopic measurement of arc plasma diameter in EDM" CIRP Annals-Manufacturing Technology 57(1): 203–207. DOI: 10.1016/j.cirp.2008.03.097.
 J. Ramkumar, N. Glumac, S. G. Kapoor, R. E. DeVor, et al., (2009) “Characterization of plasma in micro-EDM discharge using optical spectroscopy" Journal of Manufacturing Processes 11(2): 82–87. DOI: 10.1016/j .jmapro.2009.10.002.
 S. S. Mujumdar, D. Curreli, S. G. Kapoor, and D. Ruzic, (2016) “Model-based prediction of plasma resistance, and discharge voltage and current waveforms in micro-electrodischarge machining" Journal of Micro and Nano-Manufacturing 4(1): 1–8. DOI: 10.1115/1.4031773.
 E. Ekici, A. R. Motorcu, and A. Kus, (2016) “Evaluation of surface roughness and material removal rate in the wire electrical discharge machining of Al/B4C composites via the Taguchi method" Journal of Composite Materials 50(18): 2575–2586. DOI: 10 . 1177/0021998315609788.
 M. J. Haddad, F. Alihoseini, M. Hadi, M. Hadad, A. F. Tehrani, and A. Mohammadi, (2010) “An experimental investigation of cylindrical wire electrical discharge turning process" The International Journal of Advanced Manufacturing Technology 46(9-12): 1119–1132. DOI: 10.1007/s00170-009-2171-z.
 A. K. Srivastava, A. Nag, A. R. Dixit, S. Hloch, S. Tiwari, J. Scucka, and P. Pachauri, (2019) “Surface integrity in wire-EDM tangential turning of in situ hybrid metal matrix composite A359/B4C/Al2O3" Science and Engineering of Composite Materials 26(1): 122–133.DOI: 10.1515/secm-2017-0391.
 J. Qu, A. J. Shih, and R. O. Scattergood, (2002) “Development of the cylindrical wire electrical discharge machining process, Part 2: Surface integrity and roundness" Journal of Manufacturing Science and Engineering, Transactions of the ASME 124(3): 708–714. DOI: 10.1115/1.1475989.
 V. Janardhan and G. Samuel, (2010) “Pulse train data analysis to investigate the effect of machining parameters on the performance of wire electro discharge turning (WEDT) process" International Journal of Machine Tools and Manufacture 50(9): 775–788. DOI:10.1016/J.IJMACHTOOLS.2010.05.008.
 P. J. W. Mark J. Anderson. RSM Simplified: Optimizing processes using response surface methods for design of experiments. 2nd Edition. Productivity Press, 2016.DOI: 10.1201/9781315382326.