Basic experiments are carried out to analyze the size effects on the material removal rate (MRR), electrode wear rate (EWR) and relative loss rate (RLR) in the process of electrical discharge machining (EDM). Then, the relative loss rate is taken as the main criterion to decide the optimal cylindrical electrode size, which is applied to the design of the ring–shaped electrode. Finally, the advantages of the ring–shaped electrode are confirmed by comparing with the traditional plate-shaped electrode in the die-sinking electrical discharge machining experiments.

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