1. Introduction Electrical discharge machining is basically a nonconventional material removal process. This process is widely used to produce dies, punches and moulds, finishing parts for aerospace and automotive industry and surgical components [1]. This process can be successfully employed to machine electrically conductive workpieces irrespective of their shape, hardness and toughness [2-4]. During EDM process, the electrode shape is mirrored in the workpiece. The electrode dimensions are determined in such a way that spark gap between the surface to be generated and electrode is maintained as shown in Figure 1. Higher gap is required for higher removal rate but also higher gap results in poor surface quality. The performance of the EDM process is highly dependent on the material and the design of the electrodes. The electrode has two parts, i.e. the electrode tool and holder. Both these parts are often designed and manufactured into single piece. The simple electrodes are normally manufactured by conventional cutting methods, but vertical machining, casting, electroforming or metal spraying may produce complicated shape electrodes. In die-sinking electrical discharge machining process, in general, either fixed electrodes are used to produce die cavities or a rotary device works in conjunction with a CNC to control the electrode's path in various EDM profiling [5-7]. Manufacturing method of electrode also affects manufacturing time, cost and performance of EDM electrode.
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