JMS_V1_N3_RP1 Sameh Habib Journal on Material Science 2347–615X 1 3 12 21 Electrical Discharge Machining (EDM), Plastic Material, Cutting Parameters and Machine Settings Plastic materials have become the optimum choice for numerous industrial applications where the performance rather than cost is the prime consideration. The demand for the machining processes of plastics has recently increased. This work investigates the Electrical Discharge Machining (EDM) of PS-M A-463 plastic material with polystyrene base. The characteristics of PS-M A-463 plastic machined by EDM are studied in terms of machining parameters. Machining of plastics can be realized in EDM by assisting electrode method. In this method, the EDM workpiece surface is covered with an electrical conductive layer during discharge. The layer holds the electrical conductivity during discharging process. The workpiece surfaces were examined by Scanning Electron Microscopy (SEM). Moreover, surface roughness was determined with a Surface Profilometer. Experimental results indicate that the extent of delamination and surface roughness are proportional to the machining parameters. The EDM process effectively produces excellent surface characteristics and high quality holes in PS-M A-463 plastic material under low discharge energy conditions. October - December 2013 Copyright © 2013 i-manager publications. All rights reserved. i-manager Publications http://www.imanagerpublications.com/Article.aspx?ArticleId=2559