Restricted accessReview articleFirst published online 2025
A comprehensive review on process and response parameters,tool configurations,workpiece material selection,and electrolytes effect of electrochemical discharge machining process
Electrochemical discharge machining (ECDM) is an advanced hybrid machining process that combines the principles of electrochemical machining and electrical discharge machining, making it highly effective for machining non-conductive and difficult-to-machine materials. This review explores the influence of key process parameters, tool configurations, and electrolyte compositions on machining performance. It delves into the relationships between parameters such as voltage, pulse duration, tool geometry, and electrolyte concentration with critical responses like material removal rate, surface roughness, and machining accuracy. Additionally, the health implications for operators due to electrolyte usage, including exposure to toxic fumes and corrosive substances, are thoroughly analysed. By synthesizing findings from recent studies, this review provides a comprehensive understanding of optimizing ECDM for industrial applications while addressing safety concerns. It aims to guide researchers and practitioners in advancing the process efficiency and ensuring safer operational practices.
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