Abstract
This paper presents a comprehensive study of the influence of machining parameters like voltage, capacitance, and threshold on various machining performances in micro-electrical discharge drilling (MEDD) process. The workpiece material was a 1.13-mm-thick plate of titanium alloy (Ti–6Al–4 V) while the tool was a 300-μm-diameter tungsten electrode. A full factorial design (33) was employed to carry out the experiment where each of the factors has three levels. Thus, mathematical models have been developed for the major performance indices like material removal rate, tool wear rate, wear ratio, overcut, and taper by multiple linear regression analysis. Also, response surface methodology has been employed to carry out multiple response optimization and to find the optimum process parameter settings to get a desired process yield by contour overlapping method. The proposed models could be considered as valuable tools for the process planning of MEDD leading to economical machining in industry.
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