In this paper, a surface roughness (SR) study on the powder mixed electrical discharge machining of EN8 steel has been carried out. Response surface methodology has been used to plan and analyse the experiments. Average current, pulse on time, diameter of electrode and concentration of chromium powder added into the dielectric fluid of electrical discharge machining were chosen as process parameters to study the powder mixed electrical discharge machining performance in terms of SR. Experiments have been performed on a newly designed experimental set-up developed in the laboratory. An empirical model has been developed for SR. In addition, the recommended model has been verified by conducting confirmation experiments.
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