Investigating the effect of different parameters on the travelling wire electro chemical spark machining process (TW-ECSM)

Travelling Wire Electro Chemical Spark Machining (TW-ECSM) is one of the newest machining processes that has the potential to machine advanced materials such as glass, quartz, silicon nitride, various composites and ceramics, and has the factors of creating complex cavities in materials. Forging is used, especially in the aerospace industry, to produce turbine assemblies, jet engine parts, and nozzles. The Studies show that the combined methods applied to model and optimize the TW-ECSM process are reasonable. In this research, a second-order linear regression mathematical model has been used to predict the rate of chip removal during machining operations and surface roughness and their effective interactions. Then, using the Sobol statistical analysis method, various differences including voltage, wire feeding speed, electrolyte density and thickness of the work piece on the material removal rate and surface roughness have been obtained. The results obtained from the sensitivity analysis show that the voltage has the greatest effect on the chip removal rate and the wire feeding speed has the greatest effect on the surface roughness.