A study of optimization of machining parameters for electrical discharge machining of boron carbide

The correct selection of manufacturing conditions is one of the most important aspects to take into consideration in the majority of manufacturing processes and, particularly, in processes related to electrical discharge machining (EDM) of conductive ceramic materials. It is these conditions that determine such important characteristics as surface roughness, electrode wear, and material removal rate. In this article, a review of the state of art of the die-sinking EDM processes for conductive ceramic materials, as well as a description of the equipment used for carrying out the experiments, are presented. Also, a series of mathematical models will be devised using design of experiments techniques combined with multiple linear regression, which will allow us, while only performing a small number of experiments, to select the optimal machining conditions for the finishing stage of the EDM process. To that end, in this piece of work, a study will be made of the influence of the most important factors in the process of die-sinking EDM of a boron carbide conductive ceramic, namely the intensity supplied by the generator (I), the pulse time (t(i)), and the duty cycle (eta) over some of the most important technological characteristics, such as surface roughness (R-a and R-t), the volumetric electrode wear, and the material removal rate.