Effect and Optimization of Various Machine Process Parameters on the Surface Roughness in EDM for an EN19 Material using Response Surface Methodology

In today's world the manufactured product not only requires high precision and quality but also the same is to be achieved in minimum time. This has given rise to a situation which requires the knowledge of optimum values of various input parameters to maximize or minimize a particular output. In the present work effort has been made to investigate the effect of various process parameters such as Pulse ON time, Pulse OFF time, Discharge Current and Voltage on the Surface Roughness for EN19 material in die sinking EDM process. EN 19 materials, due to presence of molybdenum and chromium, finds application in products experiencing high shock. By experimentation a relationship has been established between process parameters and responses in EDM using Response Surface Methodology. In this the main objective was to minimize the Surface Roughness resulting from the experimentation conducted as per L31 orthogonal array based on RSM. Experimental data obtained were statistically analyzed and the optimized sets of values of the various parameters were depicted. It was observed that with these values improvement in surface roughness were obtained. A confirmation test was carried out to check the deviation in surface roughness value of the predicted model with experimental data and it was observed that the error was within 0.02%. (C) 2014 Elsevier Ltd.