Electro-discharge machining (EDM) technique is widely used for machining hard
metals and for performing specific tasks which cannot be achieved using conventional
technique. The most frequently used industrial application of die-sinking is mould
fabrication. In this project, the main purpose is to optimize the quality of cut for tool
steel (hardened) using Taguchi single response and multiple response performance
characteristic. The orthogonal array, single and multi-response signal-to-noise ratio and
analysis of variance are employed to study the cutting characteristic in EDM. The study
needs to optimize three parameters; current, gap and pulse duration to get best surface
roughness, material removal rate and electrode wear rate. The optimal combination of
parameters obtained in both single response and multiple response performance
characteristic shows significant improvement in cutting quality. Taguchi method is an
effective approach to optimized process parameter with given cutting characteristic
