Development of Mathematical Model for Metal Removal Rate on EDM using Copper & Brass Electrodes

Abstract Appropriate selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM). These are the conditions that determine important characteristics such as surface roughness, electrode wear, and material removal rate. In the present work experiments are conducted on EDM using Copper and Brass materials as electrodes and EN8 steel as work material. Discharge current (I P ), pulse on time (T ON ), pulse off time (T OFF ) are selected as process parameters and Metal Removal Rate (M R ) as response. Factorial design of experiment is used to find the influence of process parameters on response and a mathematical model is developed. Percentage contribution of each factor is determined using ANOVA. Optimum values of process parameters for maximum metal removal rate is obtained using MATLAB program .