A comprehensive review on powder mixed electrical discharge machining: advances in dielectric enhancement and machining efficiency
Abstract Traditional electrical discharge machining (EDM) faces several challenges in achieving high precision and superior surface quality, particularly when machining complex geometries such as injection molds and dies. In conventional EDM, common issues include a low material removal rate (MRR),...
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| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Springer
2025-07-01
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| Series: | Discover Applied Sciences |
| Subjects: | |
| Online Access: | https://doi.org/10.1007/s42452-025-07365-8 |
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| Summary: | Abstract Traditional electrical discharge machining (EDM) faces several challenges in achieving high precision and superior surface quality, particularly when machining complex geometries such as injection molds and dies. In conventional EDM, common issues include a low material removal rate (MRR), poor surface finish, excessive tool wear rate (TWR), and defects such as micropores, micromoles, and thick recast layers. To address these limitations, powder mixed electrical discharge machining (PMEDM) has been developed by mixing metal nanopowders, such as aluminium, graphite, tungsten, and silicon carbide, into the dielectric fluid to enhance machining characteristics. This comprehensive review conducts a bibliometric analysis of PMEDM research articles published in leading scientific journals. The analysis offers a country-wise distribution of publications, with India emerging as the most prolific contributor, followed by China and Saudi Arabia. The review also reveals that Alumina (Al2O3) is the most used powder in PMEDM, followed by Graphite and Titanium Dioxide (TiO2). A heat map visually illustrates the primary application areas of PMEDM, emphasizing its extensive use in mechanical and industrial engineering. The review also explores various Multi-Criteria Decision-Making (MCDM) techniques for optimizing machining parameters, identifying TOPSIS as the most popular approach, followed by AHP and VIKOR. Furthermore, the study examines essential input parameters, including dielectric fluid types, electrode materials, and powder characteristics such as size, shape, concentration and electrical conductivity—to assess their impact on key output responses like Material Removal Rate (MRR), Surface Roughness (SR), and Tool Wear Rate (TWR). The analysis also identifies optimal conditions for achieving precision and efficiency in EDM processes. This comprehensive evaluation aims to enhance the understanding of PMEDM’s capabilities and its growing significance in advanced manufacturing. Lastly, the review provides a comprehensive summary of PMEDM, highlighting the effects of nanopowder on performance parameters, albeit with some limitations. Based on the findings, potential research directions are suggested to enhance machining performance further and expand the scope of PMEDM in advanced manufacturing processes. |
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| ISSN: | 3004-9261 |