Nowadays, electrical discharge machining (EDM) has become one of the most extensively used non-traditional material removal process. In the present work, a study has been made to model and optimize the process parameters of powder mixed electrical discharge machining (PMEDM). Metal removal rate (MRR) and electrode wear rate (EWR) have been considered, as the process characteristics, to plan and analyze the experiments. Grain size of the aluminum powder (S), concentration of the powder (C), discharge current (I) and pulse on time (T) are chosen as control variables to study the process performance. The experimental results are used to develop the regression models based on second order polynomial equations for the different process characteristics. Then, a genetic algorithm (GA) has been employed to determine optimal process parameters for any desired out put values MRR and EWR.

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