Modeling and analysis of machining parameters for surface roughness in powder mixed EDM using RSM approach

Electrical discharge machining (EDM) is one of the most successful and widely accepted non-conventional machining processes for production of complex shapes with high accuracy irrespective to its hardness by removing material through electrically discharges in the presence of dielectric fluid. The paper presents the state of the art technology of high-performance machining of advanced materials i.e. Powder mixed EDM. In this article, parametric optimization of Surface Roughness (SR) study on the powder mixed electrical discharge machining (PMEDM) of H11 steel has been carried out. Response surface methodology (RSM) has been used for developing, improving and optimizing the experiments. Central composite experimental design was used to estimate the model coefficients of the process parameters. Pulse time on, discharge current and concentration of Aluminum powder added into dielectric fluid of EDM were chosen as process parameters to study the PMEDM performance. Experiments have been performed on newly designed experimental setup and the analysis of variance revealed that the factors peak current and concentration are most influential parameters affecting SR.