Abstract—This paper aims to implement Box Behnken experimental design along with response surface methodology for modelling the effect of machining parameters on the crater sizes during micro-EDM of Ni based alloy using carbide tools. The Box-Behnken design was exploited to design the experimental design array using the machining parameters, such as capacitance, voltage and tool rotational speed. Blind micro-holes were machined on the surface of Ni alloy. An important machining performance parameter crater size was observed and calculated using scanning electron microscope (SEM) image, and the mathematical model was developed by the Minitab software to predict the crater size. In addition, response surface plots were generated from the model using GNU Plot to show the effect of operating parameters and their interactions on performance parameter. The predicted values from the mathematical model were in good agreement with the experimental measurement of crater sizes. This study concludes that Box-Behnken design and response surface methodology could efficiently be applied to generate a model for calculating crater size created during micro EDM when the discharge energy is not so low.