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Abstract
Electric discharge machining (EDM) process with conductive metallic powderhas been widely used for machining of hard materials with acceptabledimensional and geometrical accuracy. However, low material removal rate (MRR) and poor surface quality limits the applications of this machining technique.In this article, effort has been made to identify the parameters that resulted in maximum MRRduringEDM operation of various die steels having similar applications (EN8, EN19 & EN24) bycopper electrode with nickel powder-mixed dielectric fluid. Since the MRR in EDM process has been affected significantly by variation inpeak current, off and on time of pulse, so these three parameters along with concentration of conductive powder have been selected as input variables in the research work. The experiments were planned and analysed using response surface methodology (RSM) technique of design of experiments (DOE).