A comprehensive review on electrochemical discharge machining (ECDM): Process configurations, optimization techniques, simulations, and challenges

Electrochemical discharge machining (ECDM) has emerged as a promising hybrid machining process, combining electrochemical and thermal effects for precision material removal, especially in non-conductive and difficult-to-machine materials. This article explores the latest advancements in ECDM, focusing on various process configurations, optimization techniques, and simulation-based studies that enhance performance and efficiency. Different tool electrode designs and discharge mechanisms are analysed to understand their influence on machining accuracy. The article also highlights the wide-ranging applications of ECDM in industries such as biomedical, aerospace, and microfabrication, showcasing its capability in precision micro-machining. Despite its advantages, challenges such as inconsistent spark generation, limited material removal rates, and tool wear remain significant barriers. Emerging solutions, including optimization, advanced electrolyte formulations, and hybrid machining approaches, are explored to address these issues. This comprehensive review provides a road map for future research and technological advancements in ECDM, paving the way for enhanced efficiency, accuracy, and industrial adoption.