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ABSTRACT
In today’s world, micro-manufacturing techniques are getting developed day by day to minimize the effort and sophistication to provide desired products. Micro forming is one of the micro-manufacturing techniques. Present research article reports on the bending of micron-thin sheets using an electric discharge machining process. The spark discharges were used to bend thin stainless steel work materials. Bend angle (BA) was analyzed by varying the duty factor (DF), gap voltage (GV), and peak current (PC). In the present work of research, response surface methodology (RSM) was implemented for the design of experiments. BA was measured using an optical microscope. The ANOVA outcomes showed that the BA was affected by all the input parameters at a 95% confidence level. Maximum value obtained for the BA was 23.76° at duty factor 70, voltage 40, and peak current 10 A. In contrast, the minimum was 4.62° at duty factor 30, gap voltage 40 and peak current 6 A. The bending surface was analyzed by Energy-Dispersive X-Ray Spectroscopy (EDS) and Field Emission Scanning Electron Microscope (FESEM) images. The EDS results confirmed the deposition of the tool material over the sample; also, FESEM images showed micro-cracks, holes at machined surface.