Electrical discharge machining (EDM) is a well-established machining option for manufacturing geometrically complex or hard material parts that are extremely difficult-to-machine by conventional machining processes. The non-contact machining technique has been continuously evolving from a mere tool and die making process to a micro-scale application machining alternative attracting a significant amount of research interests. In recent years, EDM researchers have explored a number of ways to improve the sparking efficiency including some unique experimental concepts that depart from the EDM traditional sparking phenomenon. Despite a range of different approaches, this new research shares the same objectives of achieving more efficient metal removal coupled with a reduction in tool wear and improved surface quality. This paper reviews the research work carried out from the inception to the development of die-sinking EDM within the past decade. It reports on the EDM research relating to improving performance measures, optimising the process variables, monitoring and control the sparking process, simplifying the electrode design and manufacture. A range of EDM applications are highlighted together with the development of hybrid machining processes. The final part of the paper discusses these developments and outlines the trends for future EDM research.

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State of the art electrical discharge machining (EDM)

Application of response surface methodology in describing the performance of coated carbide tools when turning AISI 1045 steel

Manufacturing and measurement of freeform optics

Advances in engineered surfaces for functional performance

Surface modification by electrical discharge machining: A review

Gloss and Surface Topography

Summary Carbide inserts of different geometry (SNG, CNMG, CNMG-MG, CPMP, and SPMP) with a variety of coatings [CVD TiN, PVD TiN, CVD (TiCN/TiC/Al 2 O 3 ), CVD (TiCN/TiC) + PVD TiN, CVD TiC, and TiN/Al 2 O 3 , …TiCN] were used to machine AISI 1018 steel at different speeds with and without a coolant. Three typical colors deep blue, blue, and golden brown were analyzed and found to contain varying amounts of oxide layers consisting of FeO, Fe 2 O 3 and Fe 3 O 4 . Chip roots from turning/drilling operations were studied for secondary shear/built-up edge formation, and temperatures calculated and related to chip color. Chip color classification, brightness, surface roughness, waviness, roundness, and chip strain were measured and evaluated.

V.C. Venkatesh

Papers

Gloss and Surface Topography

A Study of Chip Surface Characteristics during the Machining of Steel

Semi-Ductile Grinding and Polishing of Ophthalmic Aspherics and Spherics*

Semi-ductile grinding and polishing of Pyrex glass

Laser cleaning and dressing of vitrified grinding wheels