Toward green electrical discharge machining (EDM): state of art and outlook

Abstract The electrical discharge machining process is useful to manufacture complex shaped parts with high accuracy; however, it has unfriendly environmental impacts such as toxic emissions and health hazards; these impacts do not align with the recent orientation toward green industrial environments. Nowadays, researchers, practitioners, and designers focus on implementing sustainable EDM-based green environmental principles. Thus, this article presents an extensive overview of most of the enhancement and eco-friendly technologies for improving the efficiency of the EDM process (material removal rate, lower electrode wear ratio, and surface roughness) and lowering the environmental impacts. These enhancement technologies have been classified into four drivers. The advantages and limitations of each technology have been discussed. Then, the maturity of each technology has been estimated through technology readiness levels. Highlights EDM technology is in its maturity stage. The main research contributions in the last 10 years are on. The highest mature technologies are the cryogenic treatment, hybrid EDUVM, and PMEDM technologies. The CNT powder mixed EDM and the additive manufacturing technologies have been successfully applied in roughing processes and we expect more industrial applications. The high energy consumption with hybrid EDAM technology is nowadays limiting its maturity therefore further research is necessary to come to an industrially viable process.