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Spark Erosion and Material Removal Rate in Electro-Discharge Machining

Electro-discharge machining (EDM) is a non-traditional, electro-thermal manufacturing process that removes material from an electrically conductive workpiece via repeated electrical sparks generated across a dielectric-filled gap between a shaped tool electrode and the workpiece, with each spark's thermal energy locally melting and vaporizing material. Material removal rate depends on process parameters (voltage, current, pulse-on time, pulse-off time) and the workpiece's thermal properties (not its mechanical hardness or strength), distinguishing EDM from conventional mechanical machining. This falls within the domain of non-traditional/unconventional manufacturing processes in mechanical/production engineering, alongside other electro-thermal, electrochemical, and mechanical non-traditional methods.