Effects of Process Parameters on the Machining Process in Die-Sinking EDM of Alloyed Tool Steel

  • Mohamed M. Bahgat
  • Ahmed Y. ShashEmail author
  • Mahmoud Abd-Rabou
  • Iman S. El-Mahallawi
Part of the Advanced Structured Materials book series (STRUCTMAT, volume 124)


In the present research, different electrical discharge machining (EDM) process parameters are investigated on alloyed tool steel. Several experiments are conducted to investigate the effect of four process parameters, i.e., peak current (Ip), pulse on-time (Ton), polarity, and electrode material, on the machining process. The machining process is evaluated by the material removal rate (MRR), electrode wear ratio (EW%), and surface roughness (SR) as indicators of the process efficiency in terms of quality and cost. Different process parameters were experimentally investigated and statistically analyzed, and the results showed that the graphite electrode with negative polarity leads to the highest MRR, whereas the brass electrode with positive polarity leads to the lowest SR. Using a copper electrode with positive polarity resulted in the lowest EW%, while copper with negative polarity led to an instability in the process.


Die-sinking EDM Material removal rate Electrode wear ratio Surface roughness 


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© Springer Nature Switzerland AG 2020

Authors and Affiliations

  • Mohamed M. Bahgat
    • 1
  • Ahmed Y. Shash
    • 2
    • 3
    Email author
  • Mahmoud Abd-Rabou
    • 3
  • Iman S. El-Mahallawi
    • 4
  1. 1.Department of Manufacturing Engineering and Production TechnologyModern Academy for Engineering and TechnologyCairoEgypt
  2. 2.Faculty of Engineering and Materials ScienceGerman University in CairoCairoEgypt
  3. 3.Department of Mechanical Design and Production Engineering, Faculty of EngineeringCairo UniversityGizaEgypt
  4. 4.Department of Metallurgical Engineering, Faculty of EngineeringCairo UniversityGizaEgypt

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