Sustainability and recent trends in micro- electric discharge machining (μ-EDM): A state-of-the-art review

Abstract

In the era of miniature machining, micro Electrical -discharge machining (A thermal energy based materials removal process) is the most recognized non- conventional machining approaches which has the ability to generate complex 2D & 3D shapes on difficult to machine materials in a short time while maintaining high feature quality. Micro-EDM is a noncontact machining process that produces mould cavity and deep holes with less metallurgical losses, stress free and miniaturized features through careful regulation of the electrical and non-electrical process parameters. Input parameters such as current, voltage, and pulse on time, pulse off time and Duty factor play an imperative role to achieve good feature quality. This progressive review of micro–electrical discharge machining studies latest machinable composite materials (conductive), dielectric fluids, issues of surface integrity and various optimization techniques with the perspective of sustainability (i.e. high energy consumption, electrode wear, generation of hazardous dielectric waste, toxic emissions and fire hazard). A brief note on future research trends has been included in the last section. Moreover, recent applications and advantages of micro-EDM machining processes are also presented in this study.