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Evaluation of the characteristics of the microelectrical discharge machining process using response surface methodology based on the central composite design

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Abstract

Evaluation of the characteristics of a microelectrical discharge machining (Micro-EDM) process is challenging, because it involves complex, interrelated relationships so a proper modeling approach is necessary to clearly identify the crucial machining variables and their interrelationships in order to initiate more effective strategies to improve Micro-EDM qualities (electrode wear (EW), material removal rate (MRR) and overcut). This paper uses a response surface method (RSM) based on the central composite design (CCD) for Micro-EDM problems with four EDM variables (peak current, pulse on-time, pulse off-time and electrode rotation speed). Experimental results indicate that peak current is the EDM variable that most affects the Micro-EDM qualities for SK3 carbon tool steel while pulse off-time had a significant interaction with that. The results show that RSM based on the CCD could efficiently be applied for the modeling of Micro-EDM qualities (EW, MRR, and overcut), and it is an economical way to obtain the performance characteristics of Micro-EDM process parameters with the fewest experimental data.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Chiao Tung University, Taiwan, Republic of China

    Y. C. Lin & S. K. Hung

  2. Department of Mechatronic Engineering, Tahua Institute of Technology, Taiwan, Republic of China

    C. C. Tsao

  3. Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taiwan, Republic of China

    C. Y. Hsu

  4. Department of Mechanical Engineering, China University of Science and Technology, Taiwan, Republic of China

    D. C. Wen

Authors
  1. Y. C. Lin
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  2. C. C. Tsao
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  3. C. Y. Hsu
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  4. S. K. Hung
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  5. D. C. Wen
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Correspondence to D. C. Wen.

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Lin, Y.C., Tsao, C.C., Hsu, C.Y. et al. Evaluation of the characteristics of the microelectrical discharge machining process using response surface methodology based on the central composite design. Int J Adv Manuf Technol 62, 1013–1023 (2012). https://doi.org/10.1007/s00170-011-3745-0

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  • DOI: https://doi.org/10.1007/s00170-011-3745-0

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