Micro electrical discharge machining is one of the established techniques to manufacture high aspect ratio features on electrically conductive materials. This paper presents the results and inferences of an analytical study for estimating theeffect of process conditions on tool electrode wear characteristicsin micro-EDM process. A new approach with two novel factors anticipated to directly control the material removal mechanism from the tool electrode are proposed; using discharge energyfactor (DEf) and dielectric flushing factor (DFf). The results showed that the correlation between the tool wear rate (TWR) and the factors is poor. Thus, individual effects of each factor on TWR are analyzed. The factors selected for the study of individual effects are pulse on-time, discharge peak current, gap voltage and gap flushing pressure. The tool wear rate decreases linearly with an increase in the pulse on-time. A maximum increase of 28.57% has been observed between peak current of 1and 1.5 A. TWR decreases with an increase in pressure by 19.6%.
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