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The machining efficiency and productivity of the micro-electrical discharge machining (μ-EDM) process can be enhanced by the fundamental insights on the plasma-material interaction, which can be appraised via experimental and numerical analysis of discharge crater formation. The high-power density with low pulse-duration results in the transformation of the solid workpiece into liquid and even vaporisation phase to generate a crater. The crater dimension largely depends on the extent of vaporization induced recoil pressure as well as the pressure exerted by the expanding plasma channel. Efforts have been made by the researchers to analyse the plasma characteristics viz. its temperature, pressure and the role of plasma pressure on the material removal. However, there is a scarcity of the realistic data pertaining to precise plasma pressure which consequences in less accurate estimation of the numerically …