The non-traditional machining process is highly recommended for machining difficult-to-cut materials with increased hardness, toughness, work hardening effect, and poor thermal diffusivity, etc. Wire electrical discharge machining (Wire-EDM) is one of the above said processes used to machine material which are electrically conductive. One of the variants of Wire-EDM process is wire electrical discharge hybrid turning (WEDHT) process, in which, the work material is made to rotate during material removal resulting in cylindrical components manufacturing. This process follows the principle of sparking and erosion for material removal with moving wire as a tool electrode. In the present study, WEDHT process is performed on Ti-6Al-4V alloy, which has applications in the areas of biomedical, marine, chemical, aerospace, etc. 27 experiments are performed using diffusion annealed zinc coated brass wire as the tool electrode by varying servo feed, pulse ON time and wire feed rate at three different levels to study the surface quality and material removal as the output performances. Atomic force microscopy (AFM) technique gives a 3D profile of the machined surface and measures the surface roughness. These measured 3D results are validated once again in 2D surface profile meter. The factor effects of all three input parameters are analyzed individually and analysis of variance (ANOVA) for all the performance responses are studied to know the most contributing factor in deciding the surface roughness (SR) and material removal, respectively. The regression analysis is performed for the response measures and the model parameters are analysed for goodness of fit using residual plot. Pulse ON time contributes more in deciding the SR and material removal rate (MRR) of the component followed by servo feed and wire feed rate. The interaction effects of the parameters are found to be insignificant.

强烈建议采用非传统的加工方法来加工硬度高，韧性强，加工硬化效果好，热扩散系数低等难切削材料。放电加工（Wire-EDM）是上述工艺之一用于加工导电材料。Wire-EDM工艺的一种变体是线放电混合车削（WEDHT）工艺，其中，在去除材料的过程中使工作材料旋转，从而制造出了圆柱形零件。该过程遵循火花和腐蚀的原理，以移动的金属丝作为工具电极来去除材料。在本研究中，WEDHT工艺是在Ti-6Al-4V合金上进行的，已在生物医学，海洋，化学，航空航天等领域中得到了应用。使用扩散退火的镀锌黄铜线作为工具电极，通过在三个不同的水平上改变伺服进给，脉冲导通时间和焊丝进给速率，进行了27个实验，以研究表面质量和材料去除作为输出性能。原子力显微镜（AFM）技术给出了机加工表面的3D轮廓并测量了表面粗糙度。这些测量的3D结果在2D表面轮廓仪中再次得到验证。分别分析了所有三个输入参数的因素影响，并研究了所有性能响应的方差分析（ANOVA），以了解决定表面粗糙度（SR）和材料去除率的最主要因素。对响应度量执行回归分析，并使用残差图对模型参数进行拟合优度分析。脉冲开启时间在决定组件的SR和材料去除率（MRR）以及伺服进给和焊丝进给率方面起更大的作用。发现参数的交互作用无关紧要。