Abstract
Present paper highlights the features of the development of mathematical models for creating the interactive and high-order influence of various machining parameters on Radial Overcut (ROC) in Electrochemical Micromachining (EMM) process through the Response Surface Methodology (RSM). The values of the process parameters have been found out as pulse on/off ratio of 2.2, machining voltage of 4.1 V, 17.3 g/l of electrolyte concentration, voltage pulse frequency of 51.4 Hz and micro-tool vibration frequency of 226.4 Hz for the minimum ROC. The developed mathematical models will be very useful to find out the optimal parametric setting at which shortcomings like generation of micro-sparks and stray current machining can be minimised to produce high quality with high accuracy machined products at a higher rate.
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