Abstract: This paper presents the experimental investigation to determine the parametric setting for the effective and efficient machining of Monel 400 alloy by EDM process. The metal removal rate and Surface roughness has been measured for each experiment to study the effects of tool profile i.e. Flat, Convex, and Concave shape, peak current, pulse on time and pulse off time on performance during machining. The experiments have been conducted Electrical Discharge Machine model S-35; SPARKONIX is available at M/s 3M Tools, Industrial Area Phase 9, Mohali. The machining results were obtained by variation of Pulse ON Time ranging from 4 to 6 Ás, Pulse OFF Time ranging from 3 to 7 Ás, Input Peak Current ranging from 10 to 20 Amp, by changing the tool profile i.e. Flat, Concave and Convex. The optimum combination parameters for machining of Monel 400 alloy using EDM for higher MRR are Concave shape of tool, 20amp current, 4Ás of Pulse on time, 3Ás of Pulse off time. The optimum combination parameters for machining of Monel 400 alloy using EDM for lower surface roughness are Concave shape of tool, 10amp current, 4Ás of Pulse on time, 3Ás of Pulse off time.

Keywords: EDM, Tool Profile, Monel 400, MRR, surface structure.