Parametric optimization of powder mixed electrical discharge machining by response surface methodology

In the present work, a study has been made to optimize the process parameters of powder mixed electrical discharge machining (PMEDM). Response surface methodology has been used to plan and analyze the experiments. Pulse on time, duty cycle, peak current and concentration of the silicon powder added into the dielectric fluid of EDM were chosen as variables to study the process performance in terms of material removal rate and surface roughness. Experiments are performed on a newly designed experimental setup developed in the laboratory. The results identify the most important parameters to maximize material removal rate and minimize surface roughness. The recommended optimal process conditions have been verified by conducting confirmation experiments.