Electrical Discharge Machining Parameters Research Articles

Scale-dependent wetting behavior of bioinspired lubricants on electrical discharge machined Ti6Al4V surfaces

The relationships between the geometric features of material surfaces and topographically related phenomena, such as wetting, change with the scale of observation. In these studies, multiscale analyzes allow characterizing the relationships between electrical discharge machining parameters, complex surface topographic structures and contact angles. Importantly, it was possible to indicate the best scales for observing the phenomena of lubricant flow on electro-discharged surfaces and to identify key geometric parameters of the surface affecting the contact angle. This paper proposes scale-dependent contact angle analyzes of electro-discharge machined Ti6Al4V alloy for biomedical implant applications. Liquids imitating synovial fluid in joints were used as lubricants. The research focuses on comparing the impact of discharge energy on surface microtexture, chemical composition, contact angle and surface free energy. The analysis of the lubrication behavior on micro-textured surfaces in contact mechanics co-determines the tribological properties. The research results confirm the effectiveness of modeling the specific wettability of implant surfaces with bioinspired lubricants.

Bi-objective optimization of an EDM process with Cu-MWCNT composite tool using single-valued neutrosophic grey relational analysis

Purpose In many of today’s manufacturing industries, such as automobile, aerospace, defence, die and mould making, medical and electrical discharge machining (EDM) has emerged as an effective material removal process. In this process, a series of discontinuous electric discharges is used for removing material from the workpiece in the form of craters generating a replica of the tool into the workpiece in a dielectric environment. Appropriate selection of the tool electrode material and combination of input parameters is an important requirement for performance enhancement of an EDM process. This paper aims to optimize an EDM process using single-valued neutrosophic grey relational analysis using Cu-multi-walled carbon nanotube (Cu-MWCNT) composite tool electrode. Design/methodology/approach This paper proposes the application of grey relational analysis (GRA) in a single-valued neutrosophic fuzzy environment to identify the optimal parametric intermix of an EDM process while considering Cu-MWCNT composite as the tool electrode material. Based on Taguchi’s L9 orthogonal array, nine experiments are conducted at varying combinations of four EDM parameters, i.e. pulse-on time, duty factor, discharge current and gap voltage, with subsequent measurement of two responses, i.e. material removal rate (MRR) and tool wear rate (TWR). The electrodeposition process is used to fabricate the Cu-MWCNT composite tool. Findings It is noticed that both the responses would be simultaneously optimized at higher levels of pulse-on time (38 µs) and duty factor (8), moderate level of discharge current (5 A) and lower level of gap voltage (30 V). During bi-objective optimization (maximization of MRR and minimization of TWR) of the said EDM process, the achieved values of MRR and TWR are 243.74 mm3/min and 0.001034 g/min, respectively. Originality/value Keeping in mind the type of response under consideration, their measured values for each of the EDM experiments are expressed in terms of linguistic variables which are subsequently converted into single-valued neutrosophic numbers. Integration of GRA with single-valued neutrosophic sets would help in optimizing the said EDM process with the Cu-MWCNT composite tool while simultaneously considering truth-membership, indeterminacy membership and falsity-membership degrees in a human-centric uncertain decision-making environment.

Development of a machining strategy to manufacture SiSiC nuts by EDM

Today, the high-precision manufacturing of small cavities in difficult-to-machine materials is still a challenge, even more so if they need to be threaded. The machining time, the wear suffered by the electrodes and the surface finish are determining factors in the efficiency of the threading process. However, there is scant literature on this subject so there is a need to study the process and the parameters involved. Thus, this study presents a novel machining strategy for the manufacture of nuts using die-sinking electrical discharge machining (EDM). Moreover, the novelty of this strategy is that it is carried out in a single stage and with a conventional EDM generator. To do so, a design of experiments (DOE) methodology has been followed. First, the optimal machining conditions are determined by studying the influence of EDM parameters on operation variables and mathematical models are developed using multiple linear regression. These models allow the behavior of the response variables under study to be predicted. Finally, this machining strategy developed from the previous experimental results is validated in the manufacturing process of a final part, specifically a square nut. It can be concluded that the mathematical model is good enough to predict the experimental results. Thus, the new method presented and described in this present study allowed a nut to be obtained with a real arithmetic mean deviation of the roughness profile (Ra) value of 1.27 μm whereas the predicted value from the model was 1.28 μm. To do so, the machining conditions selected were: 4 A (current intensity), 5 µs (pulse time) and 0.4 (duty cycle), which also gave a material removal rate (MRR) value of 0.5370 mm3/min. The machining strategy proposed here may be used for future research works related to the manufacturing of mechanical joints made of conductive ceramic materials.

Influence of machining process of MoS2/B4C/Az31 Mg alloy composite and its tribological characteristics

The automotive, biomedical, and aerospace industries are among those with a rising need for lightweight materials with enhanced mechanical and tribological qualities. Composites based on magnesium alloys have attracted interest because of their excellent strength-to-weight ratio and promise to improve component performance. Magnesium (Mg) alloy-based composites find applications in sports and leisure equipment, aerospace, biomedical implants, and more. The research outlined here serves a critical need in the field of materials science and engineering, particularly regarding the development of advanced magnesium (Mg) alloy-based composites. In this study, we have created a new aluminum composite using the AZ31 alloy mixed with 5% boron carbide (B4C) and 5% molybdenum disulfide (MoS2) as reinforcement through a powder metallurgical technique. The magnesium alloy contains 3% aluminum and 1% zinc. Our research aims to understand the mechanical and tribological behaviors and the impact of Electrical Discharge Machining (EDM) process parameters on AZ31 magnesium alloy. We need to modify these properties for various applications. Many industrial researchers have studied the machinability of magnesium alloys using EDM. We conducted wear tests on AZ31 alloy reinforced with both B4C and MoS2 in altered quantities using a pin-on-disc setup. The outcome displays that the wear resistance of these composites is considerably better matched to other magnesium matrix composites (MMCs). We also measured various densities of the hybrid composite, including apparent density, green density, and sintered density, which were found to be 0.839, 1.495, and 1.504 g/cm3, respectively—better than other composites. In addition, the hybrid composite exhibited a substantial increase in micro hardness, reaching 22.012 HV, indicating improved wear resistance of the material. Comparatively, low density, minimum wear profile, and maximum hardness were recorded for the sample of AZ31 + 5%MoS2 + 5%B4C. The influence of EDM parameters was discussed.

Optimization and modelling of WCEDM process parameters for GZR-AA7475 HMMC using GRA and Taguchi approach

Purpose This study aims to investigate the optimal process parameters of the wire-cut electrical discharge machining (WCEDM) for the machining of the GZR-AA7475 hybrid metal matrix composite (HMMC). HMMCs are prepared with 2 Wt.% graphite and 4 Wt.% zirconium dioxide reinforced with aluminium alloy 7475 (GZR-AA7475) composite by using the stir casting method. The objective is to enhance the mechanical properties of the material while preserving its unique features. WCEDM with a 0.18 mm molybdenum wire electrode is used for machining the composite. Design/methodology/approach To conduct experimental studies, a Taguchi L27 orthogonal array was adopted. Input variables such as peak current (Ip), pulse-on-time (TON) and flushing pressure (PF) were used. The effect of process parameters on the output responses, such as material removal rate (MRR), surface roughness rate (SRR) and wire wear ratio (WWR), were investigated. The grey relational analysis (GRA) is used to obtain the optimal combination of the process parameters. Analysis of variance (ANOVA) was also used to identify the significant process parameters affecting the output responses. Findings Results from the current study concluded that the optimal condition for grey relational grade is obtained at TON = 105 µs, Ip = 100 A and PF = 90 kg/cm2. Peak current is the most prominent parameter influencing the MRR, whereas SRR and WRR are highly influenced by flushing pressure. Originality/value Identifying the optimal process parameters in WCEDM for machining of GZR-AA7475 HMMC. ANOVA and GRA are used to obtain the optimal combination of the process parameters.

Response surface methodology-based machining parameter optimisation for electrical discharge machining of stainless steel of grade AISI 4140

Electrical sparks are used in the unconventional technique of electrical discharge machining (EDM) to remove material from a workpiece. In the industrial sector, this method is often used to manufacture tough, challenging-to-machine materials like stainless steel. In this research works, we look at how to best machine stainless steel with an AISI 4140 grade, which is widely used in the aerospace and automotive sectors. The process variables, such as pulse on-time, pulse off-time, and peak current, have a big influence on the effectiveness and quality of the machining. To investigate the impacts of these factors on the machining properties, including material removal rate, tool wear rate, surface roughness, and microstructure, a systematic experimental examination is carried out in this project. The findings indicate that the ideal parameter combinations for getting the highest machining performance rely on the particular needs and limitations of the application. Various advanced optimisation techniques, such as Response Surface Methodology, are applied and compared to facilitate parameter optimisation. Moreover, the effect of a novel surface modification technique, which combines EDM with laser irradiation, on the surface properties of AISI 4140 steel is investigated. The results of this research contribute to the creation of effective and sustainable machining procedures for advanced materials by offering useful insights into the optimisation of EDM parameters for cutting AISI 4140 steel.

Experimental study on electrical discharge machining of porous and pure 316L stainless steel

Porous metal materials are widely used in heat-absorbing, biomedical parts and other fields because of their excellent mechanical properties and biocompatibility. Further applications of porous metal materials are inseparable from secondary precision machining. However, traditional cutting methods tend to compromise the original porosity of the material surface. Electrical discharge machining (EDM) is a type of non-conventional machining method which is more preferable to overcome these defects. In the present study, the main target is to investigate the effect of four input electrical machining parameters (current, frequency, efficiency and gap voltage) on the five output responses (material removal rate (MRR), electrode wear, surface roughness (SR), noise and time consumption value of environmental particulate matter (PM2.5)) when electrical discharge machining porous 316L stainless steel and compared with that of pure 316L stainless steel. The Taguchi method was employed to determine the relationship between electrical discharge machining parameters and output responses. The analysis of variance (ANOVA) was used to evaluate the effect of input parameters on output responses. The effects of electrical machining parameters on above responses were analyzed by main effects, and the order of influence was obtained, respectively. Finally, the surface morphology was observed by scanning electron microscope (SEM), and the effect of electrical machining parameters on the characteristics and formation of machined surface of porous stainless steel was mainly analyzed.

Experimental investigation of wire electrical discharge machining parameters on WE43 magnesium alloy

The influence of wire electrical discharge machining (WEDM) factors on the WE43 magnesium alloy is experimentally investigated in this work. Voltage, peak current, pulse-on time, and pulse-off time, are some of the factors taken into consideration in the study. The goal of the study is to understand how the output responses like material removal rate (MRR), surface roughness (SR), and development of recast layers are affected by the factors like voltage, peak current, pulse-on time and pulse-off time. The experimental set-up used a wire electrical discharge machine with a brass wire electrode and a workpiece made of the WE43 magnesium alloy. The L27 orthogonal array was used to alter the selected parameters through a series of experiments. The findings of the experimental investigation showed a strong link between the output responses and the electrical discharge machining (EDM) parameters. Peak current was discovered to have a direct correlation with the rate of material removal, with greater currents resulting in faster machining. SR and MRR were affected by pulse-on time and pulse-off time. Voltage had a direct impact on the development and thickness of the recast layer, with higher voltages favoring thinner recast layers.

Surface modification by electrical discharge machining: A systematic literature review and bibliometric analysis

In past few decades, the non-traditional machining techniques of electrical discharge machining (EDM) has been developed to machine materials that are difficult to cut. Additionally, the EDM method has also been employed to change the material's surface properties by applying a layer on the workpiece that is up to a few microns thick in order to improve the surface attributes. In past three decades, several numerous investigations on surface modification using EDM have been conducted globally. Present study provides a comprehensive review along with bibliometric investigation of the many approaches used to enhance the surface topology of the materials during the EDM process from 1993 to 2023. Firstly, a brief introduction to EDM-based different surface modification techniques such as electric discharge coating, surface texturing, surface alloying, and powder-mixed EDM has been given. All related documents were acquired from Scopus Core Collection and evaluated using a bibliometric analysis technique. The bibliometric analysis was examined based on the time distribution of articles, geography, top-cited documents, analysis of authors’ keywords, country-wise publications, etc. The result showed that India dominates this research area, followed by China, and there is a growing trend in the number of publications. Further, the influence of EDM parameters, dielectric fluid, tool, and work material etc. has also been discussed. The research work published related to topic has been summarized and resented in tabular format. This review offers interested scholars with a thorough overview of the significant achievements in the subject over the last few decades, including a description of the most relevant studies and their results. Moreover, potential areas for further investigation are emphasized with the goal of revitalize the interest of the worldwide scientific community in advancing this method.

A fuzzy TOPSIS method for surface integrity criteria ranking using the wire electrical discharge machining process

The objective of this study is to propose a method called the fuzzy technique for order preference by similarity to the ideal solution (F-TOPSIS) to select parameters of the wire electrical discharge machining (WEDM) process. Consequently, the parameters principally influencing the outputs of the WEDM process were identified and examined using the F-TOPSIS framework where the inputs of three decision makers, representing their opinions are incorporated into the analysis. The idea of parametric selection in a WEDM process is multicriteria-based when the production of nitinol-60 smart memory alloy (SMA) is critically considered. Current approaches of TOPSIS and analytic hierarchy process (AHP) evaluations to select the WEDM parameters fail because of the constraints of linguistic evaluations, but the use of F-TOPSIS crosses over the restriction to choose the best parameters in a WEDM process for nitinol-60 SMA. In this work, the experimental results obtained from published research were utilised to validate the proposed method. The validation of the suitability of F-TOPSIS, aided by the published work on the WEDM process, analysed the surface integrity of nitinol-60 SMA. From the five outputs, the closeness coefficients of the best and worst are found to be 0.7567 and 0.2838, respectively. This research aids the process engineer in optimising the outputs in the WEDM process, to select the best output. Hence, the research showcased how the WEDM process could select outputs efficiently, thus aiding process engineers to maintain the process to optimise parametric resource allocations and guarantee utmost productivity.

Surface investigation on RENE 41 alloy using EDM process

Machining and surface quality plays an essential role in manufacturing of components. The quality of the components depends on the surface texture of the alloy and composite. Hence, investigation on surface texture has an important role in metal industries. The current investigation deals with surface analysis on electric discharge machining (EDM) of Rene 41 alloy using atomic force microscopy (AFM). Three different set of EDM parameters were analyzed in surface texture of the Rene alloy. The pulse on time of 100,150,200 µs, current of 30, 40,50A and voltage of 30, 40, 50 V were considered. The different surface profiles and their parameters were used to enhance the surface texture of the Rene 41 alloy. Average surface roughness of 15.17 µm was achieved at 150 µs, 40 A and 40 V. The moderate surface roughness of 19.25 µm was produced. The maximum height of the roughness is 230.5 nm. It was observed at 200 µs, 50 A and 50 V. The main intend of the research work is to enhance the surface morphology of the machined zone.

Artificial neural network-based prediction assessment of wire electric discharge machining parameters for smart manufacturing

Abstract Artificial intelligence (AI), robotics, cybersecurity, the Industrial Internet of Things, and blockchain are some of the technologies and solutions that are combined to produce “smart manufacturing,” which is used to optimize manufacturing processes by creating and/or accepting data. In manufacturing, spark erosion technique such as wire electric discharge machining (WEDM) is a process that machines different hard-to-cut alloys. It is regarded as the solution for cutting intricate parts and materials that are resistant to conventional machining techniques or are required by design. In the present study, holes of different radii, i.e. 1, 3, and 5 mm, have been cut on Nickelvac-HX. Tapering in WEDM is a delicate process to avoid disadvantages such as wire break, wire bend, wire friction, guide wear, and insufficient flushing. Taper angles viz. 0°, 15°, and 30° were obtained from a unique fixture to get holes at different angles. The study also shows the influence of taper angles on the part geometry and area of the holes. Next, the artificial neural network (ANN) technique is implemented for the parametric result prediction. The findings were in good agreement with the experimental data, supporting the viability of the ANN approach for the evaluation of the manufacturing process. The findings in this research provide as a reference to the potential of AI-based assessment in smart manufacturing processes and as a design tool in many manufacturing-related fields.

A Response Surface Modeling Study on Effects of Powder Rate and Machining Parameters on Surface Quality of CoCrMo Processed by Powder Mixed Electrical Discharge Machining

Due to the high mechanical strength of the metals used in implant manufacture, which makes them difficult to work with using other machining techniques, electrical discharge machining (EDM) is frequently employed in the production of implants. In this study, the effect of powder ratio and other EDM parameters used in the machining of CoCrMo alloy, which used in implant production widely, with powder-mixed EDM on the surface roughness of the machined part was investigated through the response surface methodology. AISI 316L stainless steel was chosen as the electrode material, and Ti6V4Al was chosen as the additive powder, taking into account their biocompatibility properties. Using a Taguchi L16 array, an experimental design was created by selecting 4 levels for each parameter of additive ratio, discharge current, pulse on time (Ton), and pulse off time (Toff). The response surface method was used, along with the experimental data, to estimate how the parameters affected the arithmetic average roughness (Ra) and mean roughness depth (Rz).

Parametric Analysis of Surface Roughness and Metal Removal Rate during Electrical Discharge Machining of O1 Tool Steel

This work studies the impact of input machining parameters of Electrical Discharge Machining (EDM) on the machining process performance. Tool steel O1 was selected as the workpiece material, copper as the electrode material, and kerosene as the dielectric medium. Experimental runs have been carried out with a Design of Experiment (DOE) technique. Twenty tests are accomplished with the current range of (18 to 24 Ampere), a pulse duration range of (150 to 200 µs), and a pulse-off time range of (25 to 75 µs). Based upon the experimental study's output results, the EDM parameter's effect (voltage of power supply, discharge current, pulse duration, and pulse pause interval) on the responses of the process represented by surface roughness value Ra and Metal Removal MR rate. The results obtained by the DOE approach are analyzed by STATISTICA software. It has been concluded that an increase in the current and pulse duration maximizes both metal removal rate and surface roughness. At the same time, they are minimized by maximizing the pulse pause interval.

OPTIMIZATION OF MACHINING CHARACTERISTICS OF TITANIUM-BASED BIOMATERIALS: APPROACH TO OPTIMIZE SURFACE INTEGRITY FOR IMPLANTS APPLICATIONS

Nowadays, there has been continuous development of metallic biomaterials to meet special needs in the manufacturing of biomedical implants, units and systems so as to function well in the required environment. Developed biomaterials which possess exceptional properties in terms of biocompatibility and biomechanical compatibility require precision processing and machining to obtain the desired dimensional tolerances. Electrical discharge machining (EDM) is the noncontact or nontraditional process of machining that suits the precision machining of biomaterials. In this work, an effort was made to optimize the EDM parameters during machining of titanium-based biomaterials Ti-6AL-4V, so that the multi-objective responses could be obtained. The response surface method was used in designing the experiment, while the grey relational method was used to analyze the effect of multiple objectives into a single unit. The electrical parameters that were considered in this study include peak current, gap voltage, pulse turn-on and duty cycle. These parameters were set within the acceptable limits of the equipment. Three responses were studied, which are tool wear rates (TWRs), material removal rate (MRR) and surface roughness (SR). Using the signal-to-noise ratio and ANOVA optimum tool/electrode wear rate (TWR) is obtained at [Formula: see text][Formula: see text]g/min with process parameters [Formula: see text] A, [Formula: see text][Formula: see text]V, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text]%. Optimum values of material removal rate (MRR) are obtained as 0.01035[Formula: see text]g/min with process parameters [Formula: see text] A, [Formula: see text][Formula: see text]V, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text]%. Optimum SR is observed as 2.258[Formula: see text][Formula: see text]m with EDM process parameters [Formula: see text] A, [Formula: see text][Formula: see text]V, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text]%. Surface characteristics are verified with SEM micrographs. Whereas, grey relation analysis predicted the multi-objective optimum response characteristics. Based on the grey relation grade, experiment number 7 ([Formula: see text][Formula: see text]A, [Formula: see text][Formula: see text]V, [Formula: see text][Formula: see text][Formula: see text]s, [Formula: see text]%) secured the first rank among the experiments/trails.

Analyzing the geometrical errors of silicon nitride-titanium nitride on performing electric discharge machining using response surface methodology

Ceramic materials that find their applications in die extrusion and the balls used in bearings have a longer service life compared to that of traditional materials. Since ceramic materials are having high hardness properties, they cannot be machined traditionally, because traditional machining processes rely on the relative hardness of the tool material to the workpiece material. However, electric discharge machining aids in the machining of ceramic composites with good surface integrity performed by the copper electrodes. As a result, Spark Erosion Machining was used to investigate the geometrical tolerance of Si3N4-TiN composites. Electric discharge machining parameters range over five levels, like current from 2 to 6 A, voltage from 30 to 50 V, dielectric pressure (kg/cm2) from 16 to 24 kg/cm2, pulse on time (µs) from 15 to 19 μs, and pulse off time (µs) from 7 to 11 μs have been analyzed through an L25 orthogonal array. Main effect plots and two-dimensional and three-dimensional interaction plots have been drawn to investigate the effect of the input parameter on the output parameters like circularity, cylindricity, perpendicularity, runout, top radial overcut, and bottom radial overcut. The grey relational analysis is employed in finding the significant parameters through analysis of variance, and for each model, the regression coefficient is found. The optimal input parameters for the desired output parameters are found to be a current of 5.855 A; pulse-on time of 16.55 µs; pulse-off time of 7.22 µs; dielectric pressure of 16.32 kg/cm2; and a voltage of 40.3729 V. This research will help to enhance the geometric accuracy and precision of machined holes in Si3N4-TiN composites. The results are finally estimated using a residual data analysis, which shows that spark erosion can be improved.

Investigation study of electrical discharge machining parameters on material removal rate for AISI M2 material

EDM (Electrical Discharge Machining) is a common non-traditional machining technique for manufacture geometry parts made of intricate or extremely rigid metals that are challenging to manufacture using conventional manufacturing techniques. Electrical discharge machining by utilizing electrical discharge erosion, classify the meaning of material removal (MR). This paper's main objective is to discuss the ideal EDM parameters in order to use high-speed steel as workpiece AISI M2 and with using brass & copper as electrodes. Pulse on-time are (100, 150, and 200 µs), Current (10, 24 and 42 A) and Pulse off-time (4, 12 and 25 µs) are the input parameters effect on the material removal rate (MRR) used in the experimental work. The present study's findings shown that the highest MRR with using copper & brass as electrodes with pulse on-time 200 µs, pulse off-time 12 µs and current 42 A, at (0.31284 g/min and 0.18769) respectively, and the lowest average value of the removed material was when evaluating current 10 A, Ton is 100 µs, Toff is 4 µs, at (0.05451g/min and 0.01898 g/min) respectively.

Surface roughness and topography of EDM machining of Inconel 718

An alloy with a nickel–chromium basis known as Inconel 718 is utilised in gas turbine and jet engine applications. The machining of the Inconel 718 is challenging because of its higher strength and hardness. Electrical Discharge machining is the most common operation used for machining Inconel alloys because of its higher accuracy in machining the alloy. The machining accuracy is evaluated by the surface roughness of the material. In this research, the machining of Inconel 718 alloy using the electric discharge machining is done by varying the input parameters. Taguchi design is used for varying the input parameters of Electrical discharge machining. The efficiency in machining is evaluated by measuring the surface roughness of the Inconel alloy. The signal-to-noise ratio analysis optimises process parameters for excellent surface roughness. The analysis of variance is used to determine the impact of each input variable on the surface roughness. The result of this research is helpful for researchers and industries to select the accurate process parameter for machining Inconel 718 alloy.

Manufacturing of Mold Cavity of Micro-double Gear by WEDM

Micro-double gear is an important component that transmits power or motion as one of the key components of micro-device. In order to realize the mass and industrial production of micro-double gear, an injection mold of micro-double gear was designed. The single factor experiment and orthogonal experiment were used to optimize the process parameters of wire cut electrical discharge machining (WEDM) for machining micro-double gear mold cavity insert at the maximum cutting speed. The results show that the influence of process parameters on cutting speed is successively N, Toff and Ton , and N has the most significant influence on cutting speed, which is the key factor. When Ton =8µs, Toff =3Ton and N=5, the maximum cutting speed is 99.24mm2/min. The combination parameters of the maximum cutting speed were used to process the cavity insert of micro-double gear mold, and the cavity of micro-double gear mold was better fabricated.

Optimization of material removal rate and surface roughness during electric discharge machining of ultra‐fine grained Al6082 using Taguchi technique

AbstractIn the current work, the statistical analysis of various electric discharge machining parameters on Al6082 ultra‐fine grained aluminium alloy using Taguchi method has been presented. Repetitive corrugation and straightening (RCS) method was employed to obtain ultra‐fine grained aluminium alloy. The electric discharge machining studies were carried out for test variables – pulse off time, pulse on time and current (I). The specimens were machined in dielectric medium with current range of 3 A to 9 A in step of 3 A. Machining features of the samples analysed statistically by adopting the Taguchi's ‐ design of experiments (DOE) methodology. Impact of parameters on material removal rate (MRR) and surface roughness (SR) were examined via signal‐to‐noise ratio (S/N ratio, expressed in decibel, dB) as well as analysis‐of‐variance (ANOVA). Outcomes disclose that every selected response explicitly surface roughness (SR) and material removal rate was significantly influenced by parameters. The material removal rate was found to rise with discharge current and decrease with the duration of pulse on time and the duration of pulse off time. On the other hand, the surface roughness increased with increase in peak current and decreased with pulse on time and pulse off time especially. The machining mechanisms were examined by scanning electron microscopy.