Abstract
The work presented here gives the details of effect of process variables, namely current, pulse-on time and pulse-off time on material removal rate and tool wear rate in electrical discharge machining (EDM) of hardened EN19 steel. The copper tool electrode was used for experimentation. To study the effect of parameters on process characteristics, response surface methodology and Box-Behnken experimental design were employed. The models for responses were developed based on experimental results. Confirmative tests were conducted to validate the results, and less than 5% error was observed between predicted and experimental values of the responses. At the end, it has been found that the current has major effect on responses of EDM (material removal rate and tool wear rate), whereas there are some interaction effects possible between current and pulse-off time on material removal rate and tool wear rate.
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