Process capability of electrochemical discharge machining: A review

Abstract

Electrochemical discharge machining (ECDM) is a hybrid machining formed by combining the principles of electrochemical machining and electrical discharge machining. The ECDM is unconventional micromachining that can fabricate holes, blind holes, micro-cavities and grooves on brittle insulating materials such as quartz, glass, silicon wafers and different composites that are difficult to machine. These non-conducting materials have sundry applications such as Micro Electric-Mechanical Systems, biomedical and electronics items. The ECDM provides maximum material removal rate and good surface quality with minor tool wear. The study describes how different process parameters affect machining. The assessment mainly focuses on various tool electrode geometries and materials that are used in ECDM. The present article investigates the ramifications of different types of electrolytes and additives mixed in electrolytes used during the ECDM process on the machined zone. This paper comprehensively reviews the effect of change in applied voltage, machining gap and an inter-electrode gap in the ECDM and it also analyses the fabrication of different materials including glass, quartz, ceramics and composites.