American Journal of Mechanical Engineering. 2013, 1(6), 155-160DOI:
Abstract: Electrical discharge machining is a well-established non-traditional machining process and it has been used extensively in tool and die making industry to machine complicated contours in electrically conductive hard materials. Surface modification by using metal powder mixed in dielectric fluid or by using reverse polarity semi-sintered/sintered powder metallurgy tool electrode is an uncommon aspect of electrical discharge machining process. In present work attempts have been made to model the surface modification phenomenon by electrical discharge machining process with response surface methodology technique. Two output response parameters, surface deposition rate and surface roughness has been correlated with four input variables, peak discharge current, pulse-on time, pulse-off time, powder compaction pressure and results obtained have been discussed. Design of experiment techniques, response surface methodology and analysis of variance were carried out to model the pertinent process parameters. The average prediction errors of the developed models confirms very well with the experimental values.