An integrated framework of statistical process control and design of experiments for optimizing wire electrochemical turning process

Design of experiments (DOE) and statistical process control (SPC) have been separately used in many traditional and non-traditional machining processes, but recently these two approaches are being combined and reevaluated for more effective use and accurate conclusions. DOE and SPC are very efficient tools to maintain the process on target and within boundaries of natural variations and to achieve the maximum accuracy and effectiveness of an experimental program. This paper proposes an integrated framework of SPC and DOE to execute the experimental procedures and to investigate a reliable mathematical model for optimizing the wire electrochemical turning process (WECT). WECT is a non-traditional machining process which has tremendous applications in modern industries especially in the aerospace and military industries. Response surface methodology is used to determine the sufficient number of experiments and also the recommended values of the input parameters. Univariate and multivariate control charts are used to assess the statistical control of the output parameters. Multi-objective optimization is conducted for determining the optimum values of the input parameters.