Analysis of the Research Potential of Electrical Discharge Machining Process

Electrical Discharge Machining (EDM) is a non-traditional machining process based on electro-thermalprinciples, where electrical energy is used to generate electrical spark. In this process, material removal mainlyoccurs due to thermal energy of the spark. The important challenges in electrical discharge machining process arelow material removal rate (MRR), higher tool wear rate (TWR), lower finish of EDMed surfaces and high cost ofdielectric fluid. It is evident that the overall efficiency of EDM process is quite low. There are newer technologiesdeveloped to overcome the limitations of the EDM process. It is known that most metals can burn in oxygen undernormal conditions. Therefore, exploring this aspect leads to introduction of a new high-efficiency process known asEDM-induced ablation machining (EDM-AM) using multi-function electrode technology. Another emergingtechnology is dry electrical discharge machining. It is a technology that has the potential to replace conventionalliquid based EDM, owing to its low tool electrode wear, thin recast layer, and eco-friendliness. Another process isEDM on cryogenically cooled workpiece, which brings out a balance between removal and finish of surfaces. Theresults of experimentation show an increase in the MRR of the cryogenically cooled workpiece technique, alongwith a decrease in the surface roughness value (Ra). Therefore, the advanced techniques investigated in this paperindicate newer methods to improve the material removal rate, at the same time surface roughness and overallprocess efficiency.