Abstract: In this research, Response Surface Methodology (RSM) is used to investigate the effect of four controllable input variables namely: discharge current, pulse duration, pulse off time and applied voltage Surface Roughness (SR) of on Electrical Discharge Machined surface. To study the proposed second-order polynomial model for SR, a Central Composite Design (CCD) is used to estimation the model coefficients of the four input factors, which are alleged to influence the SR in Electrical Discharge Machining (EDM) process. Experiments were conducted on AISI D2 tool steel with copper electrode. The response is modeled using RSM on experimental data. The significant coefficients are obtained by performing Analysis of Variance (ANOVA) at 5% level of significance. It is found that discharge current, pulse duration, and pulse off time and few of their interactions have significant effect on the SR. The model sufficiency is very satisfactory as the Coefficient of Determination (R2) is found to be 91.7% and adjusted R2-statistic (R2 adj ) 89.6%.
Abstract: Electrical Discharge Machine (EDM) is especially
used for the manufacturing of 3-D complex geometry and hard
material parts that are extremely difficult-to-machine by conventional
machining processes. In this paper authors review the research work
carried out in the development of die-sinking EDM within the past
decades for the improvement of machining characteristics such as
Material Removal Rate, Surface Roughness and Tool Wear Ratio. In
this review various techniques reported by EDM researchers for
improving the machining characteristics have been categorized as
process parameters optimization, multi spark technique, powder
mixed EDM, servo control system and pulse discriminating. At the
end, flexible machine controller is suggested for Die Sinking EDM to
enhance the machining characteristics and to achieve high-level
automation. Thus, die sinking EDM can be integrated with Computer
Integrated Manufacturing environment as a need of agile
manufacturing systems.