Dry Electrical Discharge Machining(EDM) is considered as a green manufacturing process in which the liquid dielectric medium is replaced by a high velocity gas, which results improved process stability. A special tool design is adopted to find the optimum control parameters during machining of LM13 Aluminum alloy under dry EDM mode. The drilled and slotted cylindrical copper rod is used as a tool. Discharge current (I), voltage (V), pressure (P) and pulse on time (TON) are considered as varying

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... input process parameters and duty factor and tool rotational speed are chosen at the fixed level. TaguchiL27 orthogonal array is used to design the experiment and the experiments are conducted accordingly. The experimental results are analyzed using Grey Relational Analysis to find the optimal combination of the process parameters. Also, ANOVA test is conducted to ensure the conformity of the simulation results. Pulse on time is found as the most significant parameter which is followed by voltage. Furthermore, the parameters with the highest relational grade (4 A, 200 μs, 60 V and 1.5 kPa) are used in experiment to validate the simulation results. The simulation and experimental results have a good agreement with less than 0.5 % error.