oa A Comprehensive Review of Performance Improvement in Electrical Discharge Machining and Future Research Scopes

Electrical discharge machining (EDM) is a highly effective and widely utilised unconventional manufacturing technology primarily used to produce complicated forms in materials that are challenging to machine. This versatile manufacturing approach finds applications in producing diverse items such as surgical instruments, aerospace components, automotive parts, and dies and moulds. Despite its manifold advantages, this method presents notable drawbacks, including relatively modest material removal rates (MRR), significant tool wear rates (TWR/EWR), and notable surface roughness (SR). The current paper examines numerous approaches used by researchers to enhance the functionality of EDM and the scope for upcoming research. The effects of various circuit and non-circuit characteristics on performance metrics like MRR, TWR, SR, etc., are listed. The impact of different electrode material, dielectrics, and their alterations on machining performance are carefully examined. Furthermore, the paper elucidates a range of advanced EDM iterations developed to enhance performance through cutting-edge technologies. It delves into research findings concerning the environmental sustainability of EDM. It also examines various theoretical models that have been put out to describe EDM's spark generation and material removal processes. The report’s final section provides a summary of the potential areas for EDM research in the future. The investigation has shown that material removal in EDM is a complicated process. The correct electrode and dielectric material must be chosen, and their properties must be adjusted to fit the type of workpiece material for it to be effective. The choice of circuit parameters is also affected by the type of workpiece material. The effectiveness of EDM in machining metal matrix composites, ceramics, and nanomaterials requires more investigation.