Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) process is a hybrid process machining process which improves the machining characteristics and stability of process using assistive magnetic field and dielectric admixed powder. In this article, study on overcut has been performed on MFAPM-EDM machined Aluminium 6061 alloy. Discharge current, powder concentration, pulse on duration, pulse off duration, and magnetic field strength as process parameters have been varied during experimentation. Box Behnken design approach was employed for experimental design to carry out the experiments. Suitable Semi-empirical model was formulated using dimensional analysis for predicting the overcut. The empirical model developed was also compared with RSM model and was found better in predicting the response. Optimum process parameters for minimal overcut was conducted desirability function approach of RSM. Experimental results divulged discharge current as the most important parameters for overcut as compared to other process parameters on account of higher F-value. Confirmatory experiments revealed good correlation between optimum and experimental results.

磁场辅助粉末混合放电加工（MFAPM-EDM）工艺是一种混合过程机械加工工艺，利用辅助磁场和电介质混合粉末可改善加工性能和工艺稳定性。在本文中，已经对MFAPM-EDM加工的铝6061合金进行了过切研究。放电电流，粉末浓度，脉冲开启持续时间，脉冲关闭持续时间和磁场强度随着过程参数的变化在实验过程中发生了变化。采用Box Behnken设计方法进行实验设计以进行实验。使用尺寸分析来制定合适的半经验模型，以预测超切。开发的经验模型也与RSM模型进行了比较，发现在预测响应方面更好。通过RSM的合意函数方法，为最小限度的过刀量选择了最佳工艺参数。与更高的F值相比，与其他过程参数相比，实验结果表明放电电流是超切的最重要参数。验证性实验显示最佳结果与实验结果之间具有良好的相关性。