The tool wear, while machining a part in electric discharge machining (EDM) process, is of great concern in the researchers in recent years as the accuracy of tool wear directly affects the accuracy of the parts to be produced. The variation in tool wear may occur due to variation in the machining parameters such as current, spark gap, pulse duration, voltage, flushing of dielectric fluid, mode of flushing of dielectrics, taper angle of the tool, etc. This paper represents the effect of current, taper angle of tool and pulse duration on the tool wear during electrical discharge machining of EN-31 tool steel, as this is one of the materials being used increasingly in cold forming rolls, knurling tools, press tools, lathe centers, etc. The experiments have been conducted using “Central Composite Rotatable Design”. Results indicate that the tool wear could be reduced if machining is performed at low current values and low pulse duration and it could be further reduced with increase in the taper angle of tool.

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