Micro-EDM is one of an important process in machining holes which is used in wide applications to fabricate medical devices and small dies.20 samples were run by using CNC EDM machine was used for machining of conducting materials such as copper alloy workpieces for tap water dielectric by supplied DC current values (4, 6 and 10A), gap distance (0.3, 0.4 and 0.5mm) and machining time (5, 7 and 10min). Voltage of (70V) was used to cut 0.7mm thickness of copper (Cu) alloy workpieces to obtain the micro holes (400, 300, 210, 200, 120, 100, 85, 75, 70) μm.
The present work demonstrates the optimization process of hole diameter producing using electrical discharge machining (EDM) by RSM (Response Surface Methodology). The current, gap distance and machining time were the control parameters of EDM. RSM method was used to design the experiment using a second–order response surface. The process has been successfully modeled using RSM and model adequacy checking is also carried out using Minitab Software. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints.