Nonconductive ZrO2ceramic was machined by die-sinking EDM machine applying assisting electrode method. The
effect of input power on material removal characteristics was investigated. Following conclusions can be drawn from the
experimental observations and results.
1. Using adhesive copper foil as assisting electrode and copper tool electrode with –ve polarity in kerosene dielectric,
EDM of nonconductive ZrO2ceramic is done effectively (Fig. 2).
2. In the EDM of nonconductive ZrO2ceramic, the material is removed mainly by spalling (Fig. 3a). A little amount of
material is removed by melting and vaporization (Fig.3b).
3. The material removal can be increased by increasing the input power keeping other parameters constant (Fig.4).
4. After EDM, the external copper layer can be removed from the ceramic surface easily (Fig. 2).
5. Further experiments are needed to investigate the effect of higher IP on MRR.