A novel combined process of machining silicon carbide (SiC) ceramics with electrical discharge milling and mechanical grinding is presented. The process is able to effectively machine a large surface area on SiC ceramics with a good surface quality. The effect of tool polarity on the process performance has been investigated. The effects of peak current, peak voltage, pulse on-time and pulse off-time on the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated with Taguchi experimental design. The mathematical models for the MRR, EWR, and SR have been established with the stepwise regression method. The experiment results show that the MRR, EWR, and SR can reach 46.2543 mm3/min, 20.7176%, and 0.0340 µm, respectively, with each optimal combination level of machining parameters.
