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Volume 69, Issue 3
  • ISSN: 2056-5135
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Abstract

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, dies and moulds. Despite its manifold advantages, this method presents notable drawbacks, including relatively modest material removal rates (MRR), significant tool wear rates (TWR), electrode wear ratio (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 and SR 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 review’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 (MMCs), ceramics and nanomaterials requires more investigation.

© 2025 Johnson Matthey
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A Comprehensive Review of Performance Improvement in Electrical Discharge Machining and Future Research Scopes
Johnson Matthey Technology Review 69, 358 (2025); https://doi.org/10.1595/205651325X17309868513523
/content/journals/10.1595/205651325X17309868513523
/content/journals/10.1595/205651325X17309868513523
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  • Article Type: Review Article
Keyword(s): dielectrics; electrical discharge machining; environmental sustainability; material removal rates; surface roughness; tool wear rates

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