In this article, a material removal rate (MRR) and tool wear rate (TWR) study on the powder mixed electrical discharge machining (PMEDM) of EN-8 steel has been carried out. Response surface methodology (RSM) has been used to plan and analyze the experiments. Peak current, pulse on time, diameter of electrode and concentration of chromium powder added into
dielectric fluid of EDM were chosen as process parameters to study the PMEDM performance in terms of MRR and TWR. Experiments have been performed on newly designed experimental setup developed in laboratory. Most important parameters affecting selected performance measures
have been identified and optimum process conditions have been found. Also recommended optimal conditions have been verified by conducting confirmation experiments.