Mathematical modeling of material removal rate for Ti-5Al-2.5Sn through EDM process: A surface response method

Extensive work has been reported on modelling and optimization for different materials such as aluminum, iron, nickelbase alloy, C40 steel, mild steel, Ti6Al4V, HE15, 15CDV6, M-250, AISI D2 steel material etc. However model of process parameters for EDM technique on Ti-5Al-2.5Sn material has not been developed yet. This paper presents to develop of mathematical model of material removal rate (MRR) for Ti-5Al-2.5Sn using Response Surface Methodology (RSM). The electrical discharge machining is carried out on this material employing positive polarity of copper electrode. Peak current, pulse on time, pulse off time and servo voltage was considered as input parameter to correlate with MRR. Design of experiments (DOE) method and central composite response surface methodology (RSM) techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance (ANOVA). The developed model is validated with confirmation experimental data. It is observed that the developed model is within the limits of the agreeable error when experimental results. It is observed that peak current effectively influences the performance measures. The optimum machining conditions in favor of material removal rate are estimated and verified with proposed mathematical modelled results. It is observed that the developed model is within the limits of the agreeable error (about 9%) when compared to experimental results. This result leads to desirable material removal rate and economical industrial machining to optimize the input parameters.