This paper presents the results of experi mental w ork carried out in electrical discharge machining (EDM) of EN31 (air hardened steel) using three different tool materials namely copper, aluminium and EN 24, and also the problems involved in using graphite and brass as tool material. The machining process was carried out at three different supply current levels (8Amps, 12Amps, 14Amps), flushing pressure levels (10lb/sq. in, 15lb/sq. in, 20lb/sq. in) and pulse-on time (38|ìsec, 48|ìsec, 58|ìsec), and their influence on surface roughness, material removal rate, tool wear rate and taper
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