Whereas the efficiency of traditional cutting processes is limited by the mechanical properties of the processed material and the complexity of the workpiece geometry, electrical discharge machining (EDM) being a thermal erosion process, is subject to no such constraints. The base material used for this study was an AISI D2 tool steel with copper electrode. The lack of correlations between the cutting rate, the surface finish and the physical material parameters of this process made it difficult to use. This study highlights the development of a comprehensive mathematical model of Tool wear...