Abstract
The most well-known and widely used non-traditional manufacturing method is electrical discharge machining (EDM). It is well-known for its ability to cut rigid materials and high-temperature alloys that are difficult to machine with traditional methods. The significant challenges encountered in EDM are high tool wear rate, low material removal rate, and high surface roughness caused by the continuous electric spark generated between the tool and the workpiece. Researchers have reported using a variety of approaches to overcome this challenge, such as combining the die-sinking EDM process with cryogenic treatment, cryogenic cooling, powder-mixed processing, ultrasonic assistance, and other methods. This paper examines the results of these association techniques on various performance measures, such as material removal rate (MRR), tool wear rate (TWR), surface roughness, surface integrity, and recast layer formed during machining, and identifies potential gap areas and proposes a solution. The manuscript is useful for improving performance and introducing new resolutions to the field of EDM machining.
Highlights
The Electrical Discharge Machining PrincipleElectrical discharge machining (EDM) is a thermal erosion process in which a controlled electric spark discharge occurs between the tool and the workpiece
The present manuscript attempted to review the literature in the electrical discharge machining (EDM)-based fabrication process and identify gap areas, for further investigations
EDM has substantially enhanced the standard of machining operations in recent years
Summary
Electrical discharge machining (EDM) is a thermal erosion process in which a controlled electric spark discharge occurs between the tool and the workpiece. Since ionization of the dielectric medium present in the conductivity gap has created a plasma channel, the applied current produces heat, generating around a temperature of 8000 to 20,000 ◦ C at the crater spot [13,14,15]. Different input parameters include discharge current, voltage, pulse off-time, duty factor, and flushing pressure. All of these variables pulse on-time, pulsethe off-time, duty factor, andThe flushing pressure All of these variables are are critical during machining process. The influence of discharge current, voltage, pulse pulse on-time, pulse off-time, duty factor, and flushing pressure on performance measures on-time, off-time,researched.
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