The aim of this study is to develop a novel green electrical machining (GEM) using gas media
immersed in deionized water. The developed process can fulfill the environmentally friendly issue and
satisfy the demand of high machining performance. The experiments were conducted by this developed
GEM process to investigate the effects of machining parameters on machining characteristics in terms of
material removal rate (MRR), electrode wear rate (EWR), and surface roughness. Firstly, the experiments
were conducted to assess the feasibility of the new developed GEM process. Moreover, the main GEM
process parameters such as machining polarity, peak current, pulse duration, as well as the gas supply
conditions like compressed pressure were varied to evaluate effects on machining characteristics for SKD 61
steel. A high frequency digital oscilloscope was used to detect the discharge waveforms during the machining
to evaluate the effects of various machining media on gap stability, and the surface morphologies were
observed by a scanning electronic microscope (SEM) to determine the influences of electrical discharge
energy on the surface integrities. The developed GEM process revealed the potential to obtain a stabilizing
machining progress with excellent machining performance and environmentally friendly feature. As the
experimental results shown, the MRR increased with peak current, pulse duration, and compressed air
pressure. In addition, the EWR went up with peak current, and the EWR declined as further extending the
pulse duration at large peak current. The surface roughness went up with peak current, as well as the
machined surface revealed a coarser feature when the peak current was set at high value.
