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Material removal rate and electrode wear study on the EDM of silicon carbide

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(BQ) This study was made only for the finish stages and has been carried out on the influence of five design factors: intensity supplied by the generator of the EDM machine (I), pulse time (ti), duty cycle (η), open-circuit voltage (U) and dielectric flushing pressure (P), over the two previously mentioned response variables. This has been done by means of the technique of design of experiments (DOE), which allows us to carry out the above-mentioned analysis performing a relatively small number of experiments. In this case, a 25−1 fractional factorial design, whose resolution is V, has been selected considering the number of factors considered in the present study.

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Nội dung Text: Material removal rate and electrode wear study on the EDM of silicon carbide

Journal of Materials Processing Technology 164–165 (2005) 889–896<br /> <br /> Material removal rate and electrode wear study on<br /> the EDM of silicon carbide<br /> C.J. Luis, I. Puertas ∗ , G. Villa<br /> Mechanical, Energetics and Materials Engineering Department, Manufacturing Engineering Section, Public University of Navarre,<br /> Campus de Arrosadia, Pamplona, Navarre 31006, Spain<br /> <br /> Abstract<br /> In this work, a material removal rate (MRR) and electrode wear (EW) study on the die-sinking electrical discharge machining (EDM) of<br /> siliconised or reaction-bonded silicon carbide (SiSiC) has been carried out. The selection of the above-mentioned conductive ceramic was<br /> made taking into account its wide range of applications in the industrial field: high-temperature gas turbines, bearings, seals and lining of<br /> industrial furnaces. This study was made only for the finish stages and has been carried out on the influence of five design factors: intensity<br /> supplied by the generator of the EDM machine (I), pulse time (ti ), duty cycle (η), open-circuit voltage (U) and dielectric flushing pressure<br /> (P), over the two previously mentioned response variables. This has been done by means of the technique of design of experiments (DOE),<br /> which allows us to carry out the above-mentioned analysis performing a relatively small number of experiments. In this case, a 25−1 fractional<br /> factorial design, whose resolution is V, has been selected considering the number of factors considered in the present study. The resolution<br /> of this fractional design allows us to estimate all the main effects, two-factor interactions and pure quadratic effects of the five design factors<br /> selected to perform this study.<br /> © 2005 Elsevier B.V. All rights reserved.<br /> Keywords: EDM; Manufacturing; Wear; DOE<br /> <br /> 1. Introduction<br /> Electrical discharge machining (EDM) is a non-traditional<br /> manufacturing process based on removing material from a<br /> part by means of a series of repeated electrical discharges<br /> between a tool, called the electrode, and the part being machined in the presence of a dielectric fluid. At present, EDM<br /> is a widespread technique used in industry for high-precision<br /> machining of all types of conductive materials such as: metals, metallic alloys, graphite, or even some ceramic materials,<br /> of any hardness [1].<br /> The term, technical ceramic materials or advanced ceramic materials, is a relatively new term, which is applied to a<br /> range of various materials generally obtained from inorganic<br /> primary materials with a high grade of purity. These primary<br /> materials are subjected to typical processes in powder metallurgy technology and subsequently, to high-temperature sintering processes. With these materials, it is possible to obtain<br /> ∗<br /> <br /> Corresponding author. Tel.: +34 948 169 305; fax: +34 948 169 099.<br /> E-mail address: inaki.puerta@unavarra.es (I. Puertas).<br /> <br /> 0924-0136/$ – see front matter © 2005 Elsevier B.V. All rights reserved.<br /> doi:10.1016/j.jmatprotec.2005.02.045<br /> <br /> high-density parts which have excellent technical properties<br /> related to hardness, mechanical resistance, wear, and corrosion [2].<br /> In spite of their exceptional mechanical and chemical<br /> properties, ceramic materials have only achieved a partial<br /> acceptance in the field of industrial applications due to the<br /> difficulties in processing and the high costs associated with<br /> their manufacture. Over the past few years, the advances in<br /> the field of EDM have permitted the application of this technology to the manufacture of conductive ceramic materials.<br /> In line with current knowledge, the main inconvenience when<br /> applying the EDM technology to the field of ceramic materials is the electrical resistivity of these materials, where the<br /> limits are fixed between 100 and 300 cm [2–4].<br /> In this work, the selected ceramic material has been siliconised or reaction-bonded silicon carbide (SiSiC), whose<br /> field of applications is in constant growth. In this way, a material removal rate (MRR) and electrode wear (EW) study<br /> has been carried out on the influence of the following design factors: intensity (I), pulse time (ti ), duty cycle (η),<br /> open-circuit voltage (U) and dielectric flushing pressure (P).<br /> <br /> 890<br /> <br /> C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br /> <br /> This has been performed using the techniques of design<br /> of experiments (DOE) and multiple linear regression analysis. In this case, a 25−1 fractional factorial design with<br /> resolution V has been employed to carry out the present<br /> study.<br /> <br /> 2. Equipment used and conductive ceramic EDMed<br /> In this section, a brief description of the EDM machine<br /> used to perform the experiments and the conductive ceramic<br /> material studied in this work will be given.<br /> 2.1. Die-sinking EDM machine<br /> The equipment used to perform the experiments was a<br /> die-sinking EDM machine of type ONA DATIC D-2030-S<br /> (Fig. 1). Also, a jet flushing system in order to assure the<br /> adequate flushing of the EDM process debris from the gap<br /> zone was employed. The dielectric fluid used for the EDM<br /> machine was a mineral oil (Oel-Held Dielektrikum IME 82)<br /> with a flash point of 82 ◦ C. The electrodes used were made of<br /> electrolytic copper (with a cross-section of 12 mm × 8 mm)<br /> and the polarity was negative.<br /> 2.2. Reaction-bonded or siliconised silicon carbide<br /> F®<br /> <br /> silicon carThe ceramic material used was REFEL<br /> bide. This reaction-bonded silicon carbide (SiSiC) is manufactured by infiltrating silicon into a porous block made of<br /> silicon carbide powder and carbon, which is then submitted<br /> to a firing process at a specific temperature. This produces<br /> <br /> Fig. 1. EDM machine used to carry out the experiments.<br /> <br /> approximately 10% of free silicon, which fills the pores. The<br /> resulting microstructure has a low level of porosity and a<br /> very fine grain, giving a density of 3.1 g/cm3 . The mechanical resistance of the material (2000–3500 MPa to compression and 310 MPa to tension, up to 1350 ◦ C), combined with<br /> a hardness (25–35 GPa, Vickers hardness) which is higher<br /> than that of tungsten carbide (WC), explains its use as an<br /> element in high-temperature gas turbines as well as bearings<br /> and seals. Furthermore, it has a high thermal conductivity<br /> (150–200 W m−1 K−1 , 20 ◦ C) and a low thermal expansion<br /> coefficient (4.3–4.6 × 10−6 K−1 , 20–1000 ◦ C), which provides it with a good resistance to thermal shock. Reactionbonded silicon carbide performs better under chemical corrosion than other ceramic materials, such as tungsten carbide or<br /> alumina (Al2 O3 ). Therefore, it is frequently used as industrial<br /> furnaces lining.<br /> The samples of silicon carbide used in the experiments were ground sheets of the following dimensions:<br /> 50 mm × 50 mm × 5 mm. Moreover, as was mentioned earlier, the electrodes used in this case were made of electrolytic<br /> copper and subjected to a negative polarity as, according to<br /> the bibliography in the EDM field and these authors’ experience [2,5], it is the most stable and recommended way to<br /> carry out the EDM process of silicon carbide.<br /> <br /> 3. Design of the experiments<br /> In the present section, the design factors and response variables selected for this work, as well as the methodology employed for the experimentation, will be described.<br /> 3.1. Design factors selected<br /> There are a large number of factors to consider within<br /> the EDM process, but in this work the level of the generator intensity (I), pulse time (ti ), duty cycle (η), open-circuit<br /> voltage (U) and dielectric flushing pressure (P) have only<br /> been taken into account as design factors. The reason why<br /> these five factors have been selected as design factors is that<br /> they are the most widespread and used amongst EDM researchers.<br /> The intensity (I) depends on the different power levels that<br /> can be supplied by the EDM machine generator. It represents<br /> the maximum value of the discharge current intensity. The<br /> intensity values used in the EDM machine programming are<br /> power levels of the generator, these corresponding with values of the peak intensity (Ip ), which is applied between the<br /> electrode and the part to be EDMed.<br /> Pulse time or on-time (ti ) is the duration of time (in ␮s) the<br /> current is allowed to flow per cycle. On the other hand, duty<br /> cycle (η) is the percentage of pulse time relative to the total<br /> cycle time. This third factor is calculated by dividing pulse<br /> time by the total cycle time (i.e., pulse time plus pause time),<br /> where pause time or off-time (to ) is the duration of time (in<br /> ␮s) between two consecutive sparks.<br /> <br /> C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br /> <br /> Open-circuit voltage (U) is the value of the electric tension<br /> applied between the part to be machined and the electrode just<br /> before the discharge is produced. Finally, the dielectric flushing pressure (P) is the pressure of the dielectric jet removing<br /> the EDM splinter or debris from the gap zone. This pressure<br /> value is measured by a pressure gauge in the EDM machine.<br /> 3.2. Response variables selected<br /> The response variables selected for this study refer to the<br /> speed of the EDM process, i.e., material removal rate (MRR),<br /> and the efficiency of the copper electrode used, i.e., volumetric electrode wear (EW). These response variables are defined<br /> in Eqs. (1) and (2), respectively:<br /> MRR =<br /> EW =<br /> <br /> volume of material removed from part<br /> time of machining<br /> <br /> volume of material removed from electrode<br /> volume of material removed from part<br /> <br /> (1)<br /> (2)<br /> <br /> Although there are some other ways of measuring MRR and<br /> EW [6], in this work we have calculated them by the weight<br /> difference of the sample and the electrode just before and<br /> after being subjected to the EDM process. Moreover, density<br /> values of 3.10 and 8.96 g/cm3 were chosen for silicon carbide<br /> and electrolytic copper, respectively, in order to assess MRR<br /> and EW.<br /> 3.3. Fractional factorial design employed<br /> The design of experiments (DOE) technique is a powerful work tool which allows us to model and analyse the<br /> influence of determined process variables over other specified variables, which are usually known as response variables.<br /> These response variables are unknown functions of the former design variables, which are also known as design factors<br /> [7–9].<br /> Within the design of experiments, there are various types<br /> that can be considered. One of the most widely known ones<br /> is the factorial design; this consists in experimenting with all<br /> the possible combinations of variables and levels. Nevertheless, if the number of design factors is reasonably high, as<br /> in this case, and it is possible to assume that certain highorder interactions are negligible, the information on the main<br /> effects and the low-order interactions may be obtained by<br /> running only a fraction of the complete factorial experiment.<br /> These fractional factorial designs are among the most widely<br /> used types of designs for product and process design and for<br /> process improvement [7].<br /> The design finally chosen was a 25−1 fractional factorial<br /> one with four central points. This design has a resolution of V,<br /> which means that no main effect or two-factor interaction in<br /> this model is aliased with any other main effect or two-factor<br /> interaction. The addition of four central points allows us to<br /> carry out lack-of-fit tests for the first-order models proposed,<br /> where a total of 20 experiments for these first-order designs<br /> <br /> 891<br /> <br /> Table 1<br /> Levels selected for the five design factors of the 25−1 design<br /> Factors<br /> <br /> Levels<br /> −1<br /> <br /> I<br /> ti (␮s)<br /> η<br /> U (V)<br /> P (kPa)<br /> <br /> 0<br /> <br /> +1<br /> <br /> 3<br /> 30<br /> 0.4<br /> −120<br /> 20<br /> <br /> 4<br /> 50<br /> 0.5<br /> −160<br /> 40<br /> <br /> 5<br /> 70<br /> 0.6<br /> −200<br /> 60<br /> <br /> were made. In case the first-order model turned out not to be<br /> adequate for modelling the behaviour of the response variable<br /> to be studied, this was widened by adding 10 star points, thus<br /> giving a central composite design with the star points located<br /> in the centres of the faces. Thus, the case of the secondorder model consisted of a total of 30 experiments, i.e., the<br /> previous 20 of the first-order model plus the new 10 of the star<br /> points.<br /> The low and high levels selected for intensity, pulse time,<br /> duty cycle, open-circuit voltage and dielectric flushing pressure were: 3 and 5, 30 and 70 ␮s, 0.4 and 0.6, −120 and<br /> −200 V and finally, 20 and 60 kPa, respectively. The levels of the intensity factor (3 and 5) are equivalent to 2 and<br /> 6 A, respectively. A summary of the levels selected for the<br /> factors to be studied is shown in Table 1. The previous selection of variation levels was made taking into account that<br /> the authors wanted this study to be focused on the area of<br /> the finish machining stages, owing to the influence that a<br /> good surface quality has on such important properties, in the<br /> case of ceramic materials, such as fatigue and wear resistance<br /> [8,9].<br /> Table 2 shows the design matrix for the second-order models as well as the values obtained in the experiments for the<br /> response variables studied in this work, i.e., MRR and EW.<br /> As can be observed in this table, rows 1–16 correspond to the<br /> fractional factorial design, rows 17–26 correspond to the star<br /> points and finally, the central points are placed in the four<br /> last rows of the design matrix. On the other hand, the design<br /> matrix for the first-order model of MRR and EW would be<br /> obtained simply by eliminating the 10 rows corresponding to<br /> the star points.<br /> The graphs, models and tables that are to be presented<br /> in the following two sections were produced using the DOE<br /> module of the software STATGRAPHICS® plus v. 5.0.<br /> <br /> 4. Results and analysis of MRR<br /> A first-order model was proposed for the response variable MRR, where this was rejected as a result of the values<br /> obtained for the curvature test that can be seen in Table 3.<br /> As in this case the P-value, which is equal to 0.0002, is<br /> lower than 0.05, the null hypothesis that there are no pure<br /> quadratic effects in the model is therefore rejected, accepting<br /> <br /> 892<br /> <br /> C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br /> <br /> Table 2<br /> Design matrix for the second-order models of MRR and EW<br /> I<br /> 1<br /> 2<br /> 3<br /> 4<br /> 5<br /> 6<br /> 7<br /> 8<br /> 9<br /> 10<br /> 11<br /> 12<br /> 13<br /> 14<br /> 15<br /> 16<br /> 17<br /> 18<br /> 19<br /> 20<br /> 21<br /> 22<br /> 23<br /> 24<br /> 25<br /> 26<br /> 27<br /> 28<br /> 29<br /> 30<br /> <br /> ti (␮s)<br /> <br /> η<br /> <br /> U (V)<br /> <br /> P (kPa)<br /> <br /> EW (%)<br /> <br /> MRR (mm3 /min)<br /> <br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 3<br /> 5<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> 4<br /> <br /> 30<br /> 30<br /> 70<br /> 70<br /> 30<br /> 30<br /> 70<br /> 70<br /> 30<br /> 30<br /> 70<br /> 70<br /> 30<br /> 30<br /> 70<br /> 70<br /> 50<br /> 50<br /> 30<br /> 70<br /> 50<br /> 50<br /> 50<br /> 50<br /> 50<br /> 50<br /> 50<br /> 50<br /> 50<br /> 50<br /> <br /> 0.4<br /> 0.4<br /> 0.4<br /> 0.4<br /> 0.6<br /> 0.6<br /> 0.6<br /> 0.6<br /> 0.4<br /> 0.4<br /> 0.4<br /> 0.4<br /> 0.6<br /> 0.6<br /> 0.6<br /> 0.6<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.4<br /> 0.6<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.5<br /> 0.5<br /> <br /> −120<br /> −120<br /> −120<br /> −120<br /> −120<br /> −120<br /> −120<br /> −120<br /> −200<br /> −200<br /> −200<br /> −200<br /> −200<br /> −200<br /> −200<br /> −200<br /> −160<br /> −160<br /> −160<br /> −160<br /> −160<br /> −160<br /> −120<br /> −200<br /> −160<br /> −160<br /> −160<br /> −160<br /> −160<br /> −160<br /> <br /> 60<br /> 20<br /> 20<br /> 60<br /> 20<br /> 60<br /> 60<br /> 20<br /> 20<br /> 60<br /> 60<br /> 20<br /> 60<br /> 20<br /> 20<br /> 60<br /> 40<br /> 40<br /> 40<br /> 40<br /> 40<br /> 40<br /> 40<br /> 40<br /> 20<br /> 60<br /> 40<br /> 40<br /> 40<br /> 40<br /> <br /> 10.29<br /> 7.34<br /> 19.82<br /> 10.01<br /> 11.87<br /> 9.83<br /> 13.55<br /> 12.16<br /> 12.66<br /> 7.48<br /> 16.06<br /> 7.91<br /> 12.84<br /> 11.63<br /> 16.33<br /> 9.29<br /> 13.29<br /> 7.47<br /> 6.61<br /> 6.74<br /> 6.92<br /> 10.50<br /> 10.92<br /> 8.00<br /> 7.24<br /> 6.65<br /> 6.61<br /> 7.06<br /> 7.25<br /> 7.51<br /> <br /> 0.033<br /> 0.104<br /> 0.020<br /> 0.116<br /> 0.049<br /> 0.091<br /> 0.030<br /> 0.136<br /> 0.051<br /> 0.312<br /> 0.030<br /> 0.267<br /> 0.092<br /> 0.344<br /> 0.055<br /> 0.354<br /> 0.032<br /> 0.283<br /> 0.244<br /> 0.177<br /> 0.147<br /> 0.168<br /> 0.087<br /> 0.258<br /> 0.195<br /> 0.201<br /> 0.189<br /> 0.199<br /> 0.199<br /> 0.201<br /> <br /> that there is statistical evidence of curvature in the first-order<br /> model, for a confidence level of 95%. Thus, that the proposed first-order model is suitable for a significance level<br /> α of 0.05 is rejected and so, the second-order model is<br /> selected.<br /> Table 4 shows the ANOVA table for the case of the<br /> second-order model proposed, where now, the total number of degrees of freedom is equal to 29. As can be observed in this table, there are three effects with a P-value<br /> less than 0.05, which means that they are significant for<br /> a confidence level of 95%. These significant effects, arranged in order of importance, are: the main effects of intensity and voltage and finally, the interaction effect between<br /> them.<br /> On the other hand, a value of 0.9794 was obtained for the<br /> R2 -statistic, which signifies that the model explains 97.94%<br /> of the variability of MRR, whereas the adjusted R2 -statistic<br /> (R2 ) is 0.9335.<br /> adj<br /> <br /> The equation of the second-order proposed model is that<br /> shown in Eq. (3):<br /> MRR = −0.985466 + 0.151912 · I − 0.00642768 · ti<br /> +3.08858 · η − 0.000251344 · U−0.00216784 · P<br /> −0.0344143 · I 2 + 0.00035 · I · ti +0.02125 · I · η<br /> +0.00114688 · I · U + 0.0000375 · I · P<br /> +0.0000464643 · ti2 + 0.0020625 · ti · η<br /> −0.00000921875 · ti · U + 0.00001125 · ti · P<br /> −3.44143 · η2 + 0.002375 · η · U<br /> −0.0020625 · η · P − 0.0000121339 · U 2<br /> +0.00000859375 · U · P + 0.0000152143 · P 2<br /> (3)<br /> <br /> Table 3<br /> Analysis of variance table for the curvature test of the first-order model of MRR<br /> Source of variation<br /> <br /> Sum of squares<br /> <br /> Degrees of freedom<br /> <br /> Mean square<br /> <br /> F-ratio<br /> <br /> P-value<br /> <br /> Curvature<br /> Pure error<br /> Total error<br /> <br /> 0.014258<br /> 0.000088<br /> 0.014346<br /> <br /> 1<br /> 3<br /> 4<br /> <br /> 0.014258<br /> 0.000029<br /> <br /> 486.06<br /> <br /> 0.0002<br /> <br /> C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br /> <br /> 893<br /> <br /> Table 4<br /> Analysis of variance table for the second-order model of MRR<br /> Source of variation<br /> <br /> Sum of squares<br /> <br /> Degrees of freedom<br /> <br /> Mean square<br /> <br /> F-ratio<br /> <br /> P-value<br /> <br /> A:I<br /> B:ti<br /> C:η<br /> D:U<br /> E:P<br /> AA<br /> AB<br /> AC<br /> AD<br /> AE<br /> BB<br /> BC<br /> BD<br /> BE<br /> CC<br /> CD<br /> CE<br /> DD<br /> DE<br /> EE<br /> Total error<br /> Total<br /> <br /> 0.144901<br /> 0.001013<br /> 0.003173<br /> 0.066856<br /> 0.000080<br /> 0.002909<br /> 0.000784<br /> 0.000072<br /> 0.033672<br /> 0.000009<br /> 0.000848<br /> 0.000272<br /> 0.000870<br /> 0.000324<br /> 0.002909<br /> 0.001444<br /> 0.000272<br /> 0.000926<br /> 0.000756<br /> 0.000091<br /> 0.005940<br /> 0.287711<br /> <br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 1<br /> 9<br /> 29<br /> <br /> 0.144901<br /> 0.001013<br /> 0.003173<br /> 0.066856<br /> 0.000080<br /> 0.002909<br /> 0.000784<br /> 0.000072<br /> 0.033672<br /> 0.000009<br /> 0.000848<br /> 0.000272<br /> 0.000870<br /> 0.000324<br /> 0.002909<br /> 0.001444<br /> 0.000272<br /> 0.000926<br /> 0.000756<br /> 0.000091<br /> 0.000660<br /> <br /> 219.53<br /> 1.53<br /> 4.81<br /> 101.29<br /> 0.12<br /> 4.41<br /> 1.19<br /> 0.11<br /> 51.02<br /> 0.01<br /> 1.29<br /> 0.41<br /> 1.32<br /> 0.49<br /> 4.41<br /> 2.19<br /> 0.41<br /> 1.40<br /> 1.15<br /> 0.14<br /> <br /> 0.0000<br /> 0.2468<br /> 0.0560<br /> 0.0000<br /> 0.7354<br /> 0.0652<br /> 0.3041<br /> 0.7483<br /> 0.0001<br /> 0.9096<br /> 0.2862<br /> 0.5367<br /> 0.2805<br /> 0.5012<br /> 0.0652<br /> 0.1732<br /> 0.5367<br /> 0.2666<br /> 0.3123<br /> 0.7190<br /> <br /> where the variable values have been specified according to<br /> their original units. The ANOVA table shown in Table 4 can<br /> be used in order to simplify the models, especially for the<br /> case of polynomial ones. In this way, the simplified model<br /> which presents the highest value for the adjusted R2 -statistic<br /> is that shown in Eq. (4):<br /> MRR = −0.99879 + 0.152933 · I − 0.00529342 · ti<br /> +3.05541 · η − 0.000528938 · U − 0.001375 · P<br /> −0.0330263 · I 2 + 0.00035 · I · ti<br /> +0.00114687 · I · U + 0.0000499342 · ti2<br /> −0.00000921875 · ti · U − 3.30263 · η2<br /> <br /> Fig. 2. Main effects plot for MRR.<br /> <br /> +0.002375 · η · U − 0.0000112664 · U 2<br /> <br /> giving the latter a better flushing of the EDM debris. With<br /> respect to duty cycle, although its influence is not significant,<br /> MRR tends to increase until a maximum peak (near its central<br /> value of 0.5) after which MRR decreases. If pause time (to )<br /> <br /> +0.00000859375 · U · P<br /> <br /> (4)<br /> <br /> where now, the adequacy statistics are 0.9755 (R2 ) and 0.9555<br /> (R2 ). Nevertheless, the first model (with no simplifications)<br /> adj<br /> is to be considered in this study on MRR in order to take into<br /> account the contribution of all the possible effects.<br /> Figs. 2 and 3 show the main effects plot and interaction<br /> plot for material removal rate, respectively. As can be observed in Fig. 2, the most influential factors are intensity and<br /> open-circuit voltage, where the three remaining factors for<br /> a 95% confidence level have no influence on MRR. Moreover, material removal rate greatly increases when these two<br /> factors are increased, where these tendencies are the ones<br /> that one could expect a priori, as more energetic pulses usually lead to a higher material removal and on the other hand,<br /> an increase in the ionisation or breakdown voltage results in<br /> an increase in both the discharge energy and the work gap,<br /> <br /> Fig. 3. Interaction plot for MRR.<br /> <br />
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