Materials Today: Proceedings 44 (2021) 2087–2092

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Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

Recently evaluated Electrical Discharge Machining (EDM) process

performances: A research perspective
Debasish Gouda, Amlana Panda ⇑, Basanta Kumar Nanda, Ramanuj Kumar, Ashok Kumar Sahoo,
Bharat Chandra Routara
School of Mechanical Engineering, Kalinga Institute of Industrial Technology (KIIT) Deemed to be University, Bhubaneswar 751024, Odisha, India

a r t i c l e i n f o a b s t r a c t

Article history: Recently, cutting edge machining approaches are used extensively for answering multifarious issues in
Received 28 November 2020 manufacturing sectors that consist of machining larger strength materials, manufacture of intricate
Received in revised form 28 November 2020 shaped profiles, improve surface characteristics, and lower production time. In this scenario, the devel-
Accepted 6 December 2020
opment of Electro Discharge Machining (EDM) is rapidly taking place. EDM is a non-conventional
Available online 23 January 2021
thermal-based machining procedure that is used for the machining of harder materials. At large, spark
erosion is the main working principle performed in EDM. This meticulous review study provides based
Keywords:
on the recently published EDM process articles where the objective is to attempt newer work material
Tool wear rate
Surface roughness
and advanced electrode that could significantly meet industrial manufacturing domain around the globe.
Electrical Discharge Machining In addition, the concluding observations turn out with defined underlines and technological research
Gap voltage gaps making this review article useful to related academic and scientific research community with proper
identification of EDM process factors, advance work materials, material electrode tools and sustainable
dielectric for achieving favorable outcomes as a frontier machining technology.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Materials, Processing & Characterization.

1. Introduction of machining heat resistant super alloy accurately and economi-

At present, the demand for environment-friendly manufacturing
is widening very significantly. In the recent epoch, non-traditional
machining procedure has been employed for advance manufactur-
ing with defined dimensions and improved machined traits. Among
various non-traditional machining processes, EDM is the demand-
ing trailed procedure that can convince a wider array of applica-
tions in the engineering field. Its unique benefit is to machine
conductive (electrically) parts in the manufacture of aerospace,
automotive, die, mould, surgical, and components [1]. It is used
extensively due to its ability to procedure very hard material with
accuracy and precision [2,3]. It does not provide contact between
electrode and the work material. Hence, it clearly removes the
vibration, chatter, and mechanical stress problems [4]. It is the sus-
tainable manufacturing scheme offered for machining the compli-
cated work components along with for hard-to-machine and
brittle ceramics materials [5]. Further, EDM is considered to be
one of the non-traditional machining processes that are proficient
cally. This exploits electric discharges to generate heat energy by
which the work material is melted and removal from the work
material enabling it to execute on electrically conductive material
with high precision machining [6]. EDM has been considered as
cost-effective and precise machining process. A key application of
turning by EDM has appended a newer research realm [7].
The rest of this review article is categorized as follows. Section 2
discusses concept of including input parameters and output
response variables. The third section overviewed the related liter-
ature support emphasizing the magnitude of published review
articles. Then, the fourth section discusses the challenges and
issues related to EDM including selection of electrodes, and debris
removal from the machining area. Finally, Section 5 illustrates the
summary and prospects for promising future trends. Last section
accentuates with some concluding remarks.
2. EDM concept and literature support

In EDM procedure the tool electrode (conductive) with the

⇑ Corresponding author. entailed geometry is near to the work material. Nevertheless, there
E-mail address: amlanpanda@gmail.com (A. Panda). certain gap is there among the work surface and the conductive

https://doi.org/10.1016/j.matpr.2020.12.180
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials, Processing & Characterization.
D. Gouda, A. Panda, Basanta Kumar Nanda et al.
electrode. Further, the discharge voltage is utilized among the elec-
trode and the work piece that consequences for dielectric break-
down and sparks. Subsequently, multitude of heat is produced,
and the work material on the work specimen and the tool electrode
is melted and evaporated. Moreover, the dielectric cools the elec-
trode and the work piece and divulges the debris among the s gaps
to keep away from short circuit through the discharge procedure
[8]. The Fig. 1 illustrated the EDM input parameters and measured
output responses.
It was perceived from the recently published experimental and
review scientific-technical literature that the application of EDM
process using various types of electrodes and work pieces with
industry-oriented output responses for environmental sustainabil-
ity have put forward the primacy of this unconventional process. A
state of art review presented by researchers [9] introduced four
major nonconventional machining processes, EDM, abrasive water
jet machining, electrochemical machining, and laser beam machin-
ing and further discussed their intrinsic sustainability challenges
encouraging the academic researchers. Qudeiri et al. [10] docu-
mented that the effective factor influencing the Material Removal
Rate (MRR) is the discharge current during the machining of vari-
ous stainless steel on the EDM. Furthermore, the major factors
swaying the Tool Wear Rate (TWR) are the discharge current and
pulse duration time.
Czelusniak et al. [11] reviewed various materials used as EDM
electrodes. It has been pointed out that materials having thermal
conductivity, higher melting point are sufficient to be employed
as EDM electrodes. Recently, Ming et al. [12] stated that exhaust
emissions should be considered to improve the energy efficiency,
surface quality, and manufacturing productivity for green machin-
ing. Ho and Newman [1] selected EDM operating parameters with
advanced electrode design. More emphasize is given for EDM
applications demand with machining of higher strength and tem-
perature resistant materials that generate outstanding research
interests. Qudeiri et al. [13] overviewed the considerable contribu-
tions of EDM to machining of tool steels and further highlighted its
variants, and working principle for machining various grades of
tool materials with its process parameters and its performance
measures. In another work, Singh et al. [14] published a review
article based on various experimental, theoretical, modeling-
based studies considered in the EDM process of shape memory
alloys. Fig. 2 depicted the title of published significant review arti-
cles in recent years based on EDM.
Moreover, Emphasized has been given on powder-mixed EDM
mechanism by Talla et al. [15] that influencing of powder charac-
teristics and machining parameters on multi-parameter variables.
In another review, Singh et al. [16] focused on the contemporary
machining process, for instance, use of rotary tubular tool elec-
trode for effectiveness of green EDM process. Researchers [15]
Fig. 1. Input process parameters and Output responses in EDM.
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Materials Today: Proceedings 44 (2021) 2087–2092
Fig. 2. Published review articles based on EDM [1,5,13,16,17,25,45,47]
highlighted the environmental influence, personnel health and
safety of EDM procedure in the context of sustainability indicators.
The service life of dielectric life and selection of tool–work dielec-
tric combination is the main future research directions mentioned
in the review analysis. The approaches implemented for the curved
profile hole machining development have been reviewed by
together Meshram and Puri [17]. Nguyen et al. [18] summarized
that the low frequency vibration can augment the MRR because
of the controlled spark energy during the EDM process with low-
frequency vibration attached to work piece SKD61. In the review
many researchers has highlighted various electrodes, work surface
and dielectric mediums in EDM process. The main focal objective
of this paper is to significantly summarize the advance research
progress in EDM and its challenges. It has been accentuated that
various published research articles on EDM improves fastly, and
the analysis has become more very different, building significant
the deeper understanding and evaluation on its effect of machining
area exploration.
3. EDM research contributions
In academic and scientific literature, some trial investigations
have been performed in regard to higher quality machinability
indicators in EDM procedure. For instance, it is documented that
EDM preponderant output depends mostly on electrical parame-
ters (pulse-on time, peak discharge current, duty cycle, gap voltage
and pulse off time) and non-electrical factors (flushing pressure,
dielectric media, and electrode material). Moreover, very precise
control of factors can extremely ameliorate the performances [19].
The advancement of EDM machining scheme and electrode tool
materials has made a mark with a possible additional prevalent use
of the EDM procedure. Based on the EDM machine-tool-work
material database the input variable is considered. Primarily, the
evaluated output performance is based on MRR and TWR. To
achieve the manufacturing productivity objectives, minimization
of TWR and maximization of MRR are always important. [21].
The period for which the discharge is applied is known as the pulse
on-time [20]. The time wherein no discharge is applied is consid-
ered as the pulse off-time. The appropriate choice of the pulse
off-time presents steady machining [22]. Researchers [2] per-
formed experimental investigation during EDM practice using the
metal with a copper electrode from the Ti–6Al–2Sn–4Zr–2Mo alloy
as it has the more resistance, tensile strength, and yield strength.
D. Gouda, A. Panda, Basanta Kumar Nanda et al.
The base material is Ti (6242) alpha–beta alloy taken as work piece
material.
Besides, inter-electrode gap is the small gap between the elec-
trode tool and the work specimen. The gap is controlled by the
servo mechanism that retains the timely separation [23]. The
TWR is the ratio of tool weight loss (in grams) to the product of tool
material density (gm/cc) and the machining time. The ratio of
change in weight of the work material to machining time and den-
sity of the material is known as MRR [24]. In an investigation, Khan
et al. [24] explored the correlation among the diverse input vari-
able factors like pulse-on time, applied voltage, and current on sur-
face roughness, MRR and TWR. The Die Steel D-3 work material
and copper rod was used as electrode in this analysis. Muthurama-
lingam and Mohan et al. [25] enunciated that peak current and
pulse duration are significant factors on the outputs in the EDM
process. A review of the experimental research analysis reveals
that a chunk of work has been performed on different features of
EDM. With this backdrop, recently, Researcher [26] investigated
on the crystalline structure of AISI M2 high-speed steel by using
tungsten based electrode in EDM. Table 1 illustrates the EDM oper-
ations performed by researchers.
During the die sink EDM process using Inconel-625 alloy with
copper electrode Sahoo et al. [31] investigated the optimum input
parameters. Joshi et al. [32] used EN 8 steel through sinking EDM
machine, copper as electrode and dielectric fluid (distilled water).
In another study, Ganapathy et al. [33] used peak current, pulse
on time, dielectric pressure, and tool size as input parameters.
The responses were taken as MRR. The findings show that when
the peak current elevates and the pulse on-time decrease, the
MRR is more.
EDM with a rotary tool (multi-hole) using compressed argon
gas in the gap was developed by Singh et al. [34] for the processing
of titanium alloy work materials. Further, the evaluation of the
selected machined surface affirmed that the recast layers growth
with surface cracks lessened radically in the rotary tool (gas-
assisted) as compared to the stationary tool. Further, researchers
[35] indicated the prospective promotes of using enhanced moni-
toring and control technology to augment the EDM performances.
In a separate analysis conducted by Muthuramalingam [36], the
surface roughness, mean recast layer thickness, residual stress
and MRR factors have considered for assessing performances to
control the efficiency. On the basis of research performed by
[37], the performance measures of the normal tap water mixed
dielectric medium can provide remarkable performances in the
EDM process. In summary, it was noted that, more recently, supe-
Table 1
Research works on EDM operations.
Reference Input data parameters Work Material
[29] Working current, tool steel material
Pulse on time, Spark gap High Speed SteelAISI-M2 (BHN
305),
[27] pulse-on time, pulse-off time and pulsed Inconel 800
current
[28] Pulse Inconel 600 alloy
on time, pulse off time, peak current and gap
voltage.
[29] working current pulse on time and spark gap AISI M2 steel
[30] peak current, AISI 4340
pulse on time, voltage and pulse duty factor
MRR: material removal rate.
TWR: tool wear rate.
SR: Surface Roughness.
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Materials Today: Proceedings 44 (2021) 2087–2092
rior machining efficiency of Ti-5Al-2.5Sn Titanium alloy has been
attained by copper electrode through EDM operation. Over the past
years, sinking EDM has developed into one of the imperative man-
ufacturing technologies to produce very precise three-dimensional
intricate parts on any type of electrically conductive material.
4. Challenges and issues
In EDM, dielectric fluid fills up the proper gap among the work
piece and electrode. This acts as an insulator till a specific spark
gap and voltage are achieved and further maintains the insulation
among the electrode and work In general, the usually used dielec-
tric is kerosene. More weightage should be spotlighted on operator
health and machining milieu when the advance hydrocarbon based
fluids are used. Again, more viscosity is the main challenge using
pure jatropha oil [28]. The important functions of a dielectric fluid
are to absorb and remove the heat produced by the discharge from
the tool material and work [38]. In addition, the dielectric fluid
functioned as spark conductor to perform as flushing medium
and to eradicate particles. [14]. In die-sinking EDM, the arc damage
largely alleviates the quality of the machined surface [35]. The
dielectric breakdown of the insulating medium that turns into
releasing the toxic gases from the machining area [36]. Some key
challenges are presented in Fig. 3
In EDM, achievement of more machining rates with supportive
surface trait is a foremost concern. Extensive experimental
research in the area of EDM using powder-suspended dielectrics
has already been initiated. The circulation of dielectric and amount
of powder material are stated to be the main challenges [15]. The
table 2 depicts the general dielectric fluids used in EDM operation.
In another work, researchers [39] compared the canola Biodie-
sel and sunflower Biodiesel against conventional dielectric in terms
of MRR and TWR. Further, an attempt has been made by Kumar
and Mondal [29] to find out the correct input variables that will
provide paramount machined quality part during EDM of AISI M2
steel using electrode EDM tool tungsten–thorium type and com-
pared the finding derived from various optimization techniques.
Gugulothu [40] studied the sway of deionized water as a dielec-
tric fluid, drinking water and mixed (25% deionized water + 75%
drinking water) with Ti-6Al-4V work and copper (electrode mate-
rial). It was claimed from the analysis that, drinking water as
dielectric fluid shows higher MRR and lower the surface roughness.
As sustainable dielectric fluid, jatropha curcas oil based bio diesel
has been been used by Khan et al [28]. With significant potential.
Rizvi et al. [30] concluded that the most contributing variable for
Output Electrode material
responseparameters
MRR, TWR, SR tungsten–thorium electrode
MRR, SR electrode was made up of oxygen
free
high conductivity copper
MRR, EWR Copper, Brass,
and Copper tungsten electrodes
MRR, EWR & SR tungsten-thorium electrode
SR Cu-W electrode
D. Gouda, A. Panda, Basanta Kumar Nanda et al.
Fig. 3. some key challenges of EDM process.
Table 2
Sustainable dielectric fluid during EDM operation.
Author Dielectric fluid
[28] jatropha curcas oil based biodiesel
[36] normal tap water mixed deionized water
surface roughness is pulse on time during AISI 4340 grade machin-
ing in the EDM process (die-sinking). In addition, Meshram and
Puri [27] explained multifarious mechanisms and methods for
the uses in the field of molding, aerospace, and automative sectors.
In EDM, the localized heating grounds for the electrode evapora-
tion in the plasma zone and afterwards the material is eroded
known as EDM debris [7]. More importantly, EDM of nimonic
alloys, find its many application of gas turbine, steam turbine,
biomedical due to its higher specific strength and corrosion resis-
tance at higher temperatures [41]. Novel path for the Fe-Cu alloy
formation using EDM was investigated by Katiyar et al. [42] where
the discharge can turn to a more temperature and successive
quenching resulted in formation of alloy. Further, the characteriza-
tion of eroded parts proves the Fe-Cu alloy formation.
Kumar et al. [43] evaluated the depth of Heat Affected Zone,
mean crater diameter, and the surface roughness of the aluminium
based composite machined during the EDM process at various
machining surroundings. In another work, Das et al. [44] recom-
mended that the reliable jatropha bio dielectrics are to flush with
(0.30 m/ sec to 0.40 m/sec) to meet the viscous influence for indus-
trial uses. Bhadauria et al. [5] discussed regarding diverse
approaches like Die sinking EDM, Micro-EDM, and powder mixed
EDM to machine difficult material by EDM methods, its variables,
and outcomes of the process factors on EDM machining outstand-
ing characteristics. Kumar et al. [45] addressed the principle of
electric erosion and the effect of the desired surface characteristics
of the processed composites. The findings revealed that the current
is the prevailing variable influencing the MRR and surface rough-
ness during machining of EDM process using MMC-Metal matrix
composite. Researchers [46] used compressed argon gas during
EDM with input variables to exploit the surface finish of machined
parts.
One of the problems associated in the EDM is flushing of eroded
debris particles in the machining sector. The eroded debris particles
cause an arcing and short out in the gap causing lower machined sur-
face roughness [16]. The rapid manufactured electrode with involve-
ment of cryogenic cooling was observed to machine the more precise
complex shape characteristics in terms of dimensions on the work
piece [47]. The benefit of using copper tungsten electrode as an
extremely fine wear resistance to progress the performance with a
remarkable higher-quality surface finish of machined surface [48].
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Materials Today: Proceedings 44 (2021) 2087–2092
The challenges faced by the scientific researchers include the selec-
tion of coating material, coating thickness, and methods of creating
these coatings. Research is keeping up to development of a compos-
ite material that fulfils the necessity of tool properties. The amalga-
mation of more thermal conductivity and wear resistance of tool
material is an important requirement of the electrode. The proper
selection of tool material is important for attaining futuristic proper-
ties [49]. Over the last decades, EDM technology has developed sig-
nificantly. The aforesaid literature survey has comprehensively
conversed the recent advanced technical knowledge and concen-
trated on the general dilemmas happening in the procedure of mot-
ley groups of tool-work materials combinations. The examination of
material properties and the suitable selection of uncontrollable
parameters for a particular candidate material are essential for effec-
tive application of EDM. The advanced acceptable industrial dielec-
tric medium may be further used in EDM. The influence of the
EDM input process factors on nanostructured tungsten without
metallic binder concerning with contemplated machining perfor-
mance proposing as future research work. Contrariwise, the adaptive
controlling of the input factors during EDM process may be research
analysis for researchers. Further, investigating few more sustainable
dielectrics and erosion slurry management would be better research
directions. Above all else, The EDM process requires to be rejuve-
nated to remain economical in offering quintessential role in the
machining sector with hard-to-cut materials. Under these circum-
stances, the quantitative and qualitative characterization of the
multiple-measured responses may be must be further studied. The
different types of electrodes used in the EDM process is shown Fig. 4
Continuously, it is a salient challenge for scientific researcher
teams to create complicated design along with finer machined parts
using EDM process. For machining difficult to cut materials tungsten
based alloy, tool steel, ceramic composites, aerospace alloys with
fatigue, hardness, toughness, corrosion resistance, characteristics
etc. have been ingeniously generated. In addition, to congregate
the recent industrial constraints, advance of the mechanical and
thermal characteristics of the material(s) are highly necessitated
[50,51]. Tooling wear happens at a quicker rate may at higher tem-
perature during machining of nimonic alloys. This significantly
maintains higher strength that does not maintain the plastic defor-
mation needed for chip formation and rise in the thermal stress due
Fig. 4. Different types of electrodes [11]
D. Gouda, A. Panda, Basanta Kumar Nanda et al.
to smallest thermal diffusivity turns into higher temperature gener-
ation at the tool edge [52]. Another important issue is the analysis of
debris. The investigation of debris materials may play a pillar role in
the deeper understanding of the alloy formation method in EDM
process. Due to their immiscible behavior, the Synthesis of Fe-Cu
alloy is complex by equilibrium procedures. The Fe-Cu alloy forma-
tion is an enormously challenging issue using traditional method of
alloy formation [42]. Further, vibration integrated to work part in
EDM makes MRR and surface roughness to be ameliorated creating
a huge prospect in this field. Vibration affixed to work piece in EDM
will steps forward considerably drain of chips and machining stabil-
ity. The number of instances of the discharge amid the electrode and
the work material is significantly augmented so machining produc-
tivity and quality will proliferate [53].
5. Summary and future research directions
Over the last decades, EDM technology has developed signifi-
cantly. The aforesaid literature survey has comprehensively con-
versed the recent advanced technical knowledge and
concentrated on the general dilemmas happening in the procedure
of motley groups of tool-work materials combinations. The exam-
ination of material properties and the suitable selection of uncon-
trollable parameters for a particular candidate material are
essential for the effective application of EDM. The advanced
acceptable industrial dielectric medium may be further used in
EDM. The influence of the EDM input process factors on nanostruc-
tured tungsten without metallic binder concerning with contem-
plated machining performance proposing as future research
work. Contrariwise, the adaptive controlling of the input factors
during EDM process may be research analysis for researchers. Fur-
ther, investigating few more sustainable dielectrics and erosion
slurry management would be better research directions. Above
all else, The EDM process requires to be rejuvenated to remain eco-
nomical in offering a quintessential role in the machining sector
with hard-to-cut materials. Under these circumstances, the quanti-
tative and qualitative characterization of the multiple-measured
responses may be may be further studied.
6. Conclusion
This review recapitulates the relevant research on EDM process.
It is discernable from this study that the different reviews have been
reported by various researchers in the light of advanced electrode,
electrolyte in EDM process. This review further elaborates the chal-
lenges involved in the process with development of EDM tool for
various hardened steel and aerospace material. It is pertinent to
note that deletion of debris from the cutting zone and advanced
electrode and its design will need for pondering for scientific
researchers with effective controls of input machining factors. In a
quest to meet increasing demand of EDM processes, scientific
researchers have explored hybrid machining and with various ways
to recuperate the sparking efficiency. This will definitely helpful for
research avenues working on this advanced non-traditional machin-
ing process. Development of newer technologies for EDM will defi-
nitely accentuated with the encouraged result in precision industry
with targeting machining productivity and performance.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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Materials Today: Proceedings 44 (2021) 2087–2092
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