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The unconventional machining processes are popular in machining the difficult to cut type complex contour/ profile. The key parameters are to be machined with care as they directly affects the function and non key dimensions are machined with other than consideration of functional aspect, like design, passage. That means accuracy is less important in those dimensions but finish is to be good. So the machining of engineering materials does not always require optimizing parameters based on multiple responses. This investigation focuses on the sensitiveness of Wire EDM of 12X18H10T - Stainless Steel and identifying the parameters contribution and establish mathematical model to predict values without trial. An austenitic alloy 12X18H10T - Stainless Steel exhibits its inherent mechanical properties even when it expose to extremely high temperature. Ithas potential application in aerospace engine components manufacturing. This investigation utilized the Taguchi L9 experiential Design with factors of Pulse off Time, Wire Tension, Pulse on Time, and Wire Feed Rate. This study aims to examine Maximize the rate of machining with Taguchi approach in the process of Wire EDM of 12X18H10T - Stainless Steel and establish a mathematical model to predict the highly influencing parameter(s) for desired rate of machining.

Objectives Magnesium alloys are the potential candidate for metallic implants due to their excellent mechanical characteristics, biodegradable nature, and properties similar to human bone. However, a high degradation rate is primary obstacle in implementing these alloys as biodegradable orthopedic implants. Powder-mixed electric discharge machining (PMEDM) is an emerging method of surface modification of metallic alloys that can be implemented to improve the corrosion resistance of Mg alloys. Therefore, PMEDM using zirconium (Zr) and manganese (Mn) powder particles has been proposed to modify the surface characteristics of Mg-4Zn alloy. Materials and Methods In the present work, Zr and Mn powders have been used in varying concentrations during PMEDM of Mg-4Zn alloy. Experiments were conducted as per mixed design L18 orthogonal array (OA). Taguchi and Grey Relational Analysis (GRA) have been used to optimize the process parameters. Analysis of response characteristics, namely material removal rate (MRR), surface roughness (SR), and thickness of the alloyed layer (TAL), has been carried out at different values of input variables (like powder additives (Pa), powder concentration (Cp), peak current (Ip), pulse on time (Ton) and duty cycle (DC)). The corrosion analysis was carried out by immersing the specimen (machined at an optimized setting) in simulated body fluid (SBF). Results It is observed from the analysis that Cp, Ip, and Ton play a pivotal role in evaluating response characteristics. The favorable setting suggested by the gray approach is Pa: Zr; Cp: 2 g/l; Ip: 4A; Ton: 50 μs; DC: 80%, while responses at this setting are confirmed by confirmation experiments with MRR: 32.14 mm3/min; SR: 5.578 μm and TAL: 8.28 μm. The immersion test signifies that the corrosion rate (CR) of PMEDMed sample (3.20 mm/year) is 40.74% lesser than the corrosion rate of polished sample (5.40 mm/year). Conclusion Zr powder shows better performance in terms of higher MRR, lower SR and higher TAL as compared to Mn powder during the PMEDM process. The corroded surface of polished sample exhibited larger size micro pits and cracks than the machined sample, which concluded that surface modification of MZ-4Zn alloy via PMEDM is a powerful tool to enhance its corrosion resistance.

This paper presents the influence of wire electrical discharge machine (WEDM) cutting parameters on the magnetization characteristics of electrical steel. The demand for electrical steel keeps increases because of the high demand of electrical motor and transformers for electric vehicle and smart grid applications. The magnetization characteristics of the laminated steel used in these machines have dominates the performance of these machines. The cuttings methods and cutting parameters have huge role in deciding the magnetization characteristics. In this work, WEDM is used to cut the electrical steel in to small pieces. The cutting parameters such as current, feed rate and on-time of WEDM are varied by keeping two of these parameters fixed and one varied. From the electrical steel sheet, 18 sample small electrical steel pieces are obtained at various cutting parameters of WEDM. The magnetic field – magnetization characteristics are obtained using vibrating sample magnetometer (VSM). This analysis shows that higher current, lower on-time and higher feed rate is providing higher magnetization.

In current exploration, a die-sinking EDM technique on two various Ni based alloy materials (Alloy 625, Alloy 718) were planned to optimize numerous performance attributes depends on Taguchi method. Nickel based Super alloy like Alloy 625 and Alloy 718 are mostly used in aerospace, marine, nuclear industries due to its remarkable chemical and mechanical properties. Experimentation have been proposed by Taguchi’s design to see impact of four input process machining factors like pulse on time, off time, current and tool rotation on material removal rate, electrode wear rate, average surface roughness and overcut. A combined route of optimization of satisfaction function with Taguchi method was used for the multiple performances optimization. The optimum and most cogent parametric setting for machining was obtained at: [pulse on time = 100 µs, pulse off time = 50 µs, current = 17A, tool rotation = 825 rpm] for alloy 625; [pulse on time = 300 µs, pulse off time = 75 µs, current = 14A, tool rotation = 925 rpm] for alloy 718.

Efficient and cost effective utilization of WEDM process is a challenge for leading edge era of manufacturing because of the complex and non-linear behavior of the process. The current study focuses on an experimental inquiry carried out for WEDM of Nitronic-30 to obtain optimum process parameters for improved surface roughness (SR) and material removal rate (MRR), Nitronic-30 is austenitic stainless steel offers high strength with good corrosion resistant property which high potential in applications such as automotive parts, aqueous applications, solid handling equipment. Therefore, multi-response optimization of Nitronic-30 on WEDM is very essential. Experiments were carried out with Taguchi's DoE and a L9 orthogonal series, with machining parameters like pulse on time (Ton), pulse off time (Toff), and peak current (IP). Minitab-17 software was used to evaluate response variables such as material removal rate and surface roughness. Analysis of variance (ANOVA) and SN Ratio plot of GRG indicates that peak current is the most important parameter. Grey Relational Analysis (GRA) provides optimal process parameters like pulse on time 124 machine units, pulse off time 40 machine units and peak current 230A for optimal response variables as 4.019 µm SR and 8.683 mm3/min MRR.

In the present research work, experimental and finite elemental analysis of powder mixed electric discharge machining of Ti-Nb-Ta-Zr alloy has been presented. The mechanism for the materials removal has been numerically simulated. A mathematical model for the surface roughness has been presented. The effect of process parameters such as peak current, pulse-on, pulse interval, and voltage on the temperature distribution in surface has been investigated. The crater geometry of PM-EDM and EDM formation has been compared. The results showed that PM-EDM produced small micro-size craters as compared with EDM. The PM-EDM produced better surface roughness. The predicted surface roughness for the 0.78 μm in the case of PM-EDM.

A detailed experimental research study on wire lag phenomena, gap force, and wire lag compensation has been carried out on M2 tool steel material to overcome the error in dimensional accuracy for circular or curved profile job cutting in the wire electrical discharge machining. The design of experimental planning was made based on Taguchi methodology to determine the effect of the WEDM input control parameters on the wire lag related to different machining criteria, as well as the material removal rate, surface finish characteristic in terms of Ra values, spark gap, and specific energy consumption in this research work. The frequency, pulse on time, peak current, wire feed, workpiece height and wire tension, cutting diameter, and the span in between wire guide and job surface are considered as input control parameters for the present study. Parametric analysis shows that wire lag increases with workpiece height and wire lag compensation value increase rapidly with the decrease of job diameter. Parametric analysis is also carried out for MRR, surface roughness, spark gap, and specific energy consumption for optimum output. A further key finding is identified that the energy utilization efficiently increases with larger height job cutting in the WEDM process.

Wire-cut Electrical Discharge Machining (WEDM) is a notable machining process to produce exact and accurate complex shape products. As a high corrosion resistance with high hardness and strength, N...

The wire-electrical discharge machining method is one of the important modern manufacturing methods and has been widely used especially in the die manufacturing industry. The quality of the surfaces of the tools used in production, such as extrusion dies, punches, which are in contact with the produced product, is very important. The surface roughness of the extrusion die will affect the final product surface quality. In this study, pulse times, pulse pause times, wire feed speeds, and workpiece (die) thicknesses are variable, and their effect on hardness, surface roughness change, and material removal rate were researched. The study was carried out using steel material (cold work tool steel) used in products such as extrusion dies and punch. The effect of the thickness of the workpiece (die) processed by the WEDM method on the surface roughness was investigated, and, unlike the literature, the variation of the surface roughness of the wire entry side and wire exit side on the WEDMed surface was investigated. A slightly higher surface roughness was measured at the wire exit side compared to the wire entry side. In addition, the hardness of the die, which is in constant contact with the product produced, is also very important. The hardness of the die will directly affect the die life. In the study, carbon concentration changes were determined depending on the process parameters on the WEDMed surfaces, and the relationship between carbon concentration and microhardness was revealed. As a result, it was observed that the surface integrity depends on the process parameters, so the process parameters should be selected according to the desired properties of the produced parts.

Purpose The electric discharge machining (EDM) involves electrons discharged from the electrode and machining progresses due to the removal of the material from the component. This a thermal-based machining process primarily used for hard to machine components with conventional methods. This process is used to make intricate cavities and contours. The fabricated part is the replica of the tool material with high surface finish and good dimensional accuracy. This study aims to evaluate the comprehensive effect of process parameters on electric discharge machining of maraging steel. Design/methodology/approach Multiple criteria Decision making (MCDM) techniques are used to select the best parameters by comparing several responses to achieve the desired goal. There are different MCDM techniques available for optimization of machining parameters. In the current investigation, multi-objective optimization by data envelopment analysis based ranking (DEAR) approach was used for machining Maraging C300 grade steel. Findings The Taguchi L9 runs were planned with process parameters such as current (Amp), Tool diameter (mm) and Dielectric pressure (MPa). The effect of process parameters on the responses, namely, material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) were evaluated. High MRR is found at 15 A current, 14 mm tool diameter and dielectric pressure of 0.2 MPa. Optimum process parameters experiment showed reduced crack density. Originality/value An effort was made successfully to enhance the responses using the DEAR method and establish the decision making of selecting the optimal parameters by comparing the results obtained by machining maraging steel C300 grade.

This paper considers the technology of electrical discharge machining of steel friction pairs and reports the results of experimental studies. Analysis of the experimental studies has shown that increasing the "anode-cathode" voltage leads to a sharp decrease in the micro-hardness of the surface layer. The study has also made it possible to determine the characteristic dimensions of the structural elements, the height parameters of surface roughness. The elemental composition of the resulting surface of a steel 15KHGN2TA sample differs from the composition of coatings and the surface layers of samples modified by electrical discharge machining involving various electrodes. Under the "anode-cathode" system operation mode, a thin layer of coating with a stable modified structure forms on the surface of the cathode due to dissipative processes. It is shown that the height of surface irregularities on sections after friction is higher than on the surface sections outside the friction flow, which is associated with the formation of a friction transfer film on the samples' surface. It was established that the interaction of friction of steel samples treated by electrical discharge machining forms a thin film on the surface of friction of steel samples, which leads to a change in the relief of surfaces with an increase in the height of the micro-protrusions, as well as the structuring of the transfer film in the direction of sliding. The effect of machining steel surfaces by electrical discharge on the wear resistance of metal-polymer tribosystem was established. The implementation of the devised technology could provide a significant increase in the wear resistance of metal-polymer tribojunctions

Diamond is a typical super-hard material with very high thermal conductivity. This makes is highly suited to heat dissipation from electronic microchips. The stability of its chemical lattice structure, however, means it has no free-electrons and a high melting point, making machining of diamond difficult. In this study, a micro-energy w-EDM (wire-Electric Discharge Machining) power source with dual-capacitance is designed for using high-frequency spark erosion to precisely cut boron-doped nano-polycrystalline diamond (B-NPD) material. The power source design consists of a dual-capacitance circuit, a programmable logic circuit (PLC), and a metal–oxide–semiconductor field-effect transistor (MOSFET). By utilizing a high-frequency switching dual-capacitance circuit, each capacitor has enough charge/discharge time to create a micro-energy pulse train of uniform iso-pulse on-time (τon) and iso-pulse peak current (Ip). Material removal occurs rapidly so that micro-quantities of diamond are readily removed to reduce the probability of thermal damage and graphitization. The technique allowed successful machining of a highly consistent plate-finned diamond heat-sink array and trapezoid-pillar diamond heat-sink array. Furthermore, manufacturing using the designed low-energy power-source is highly efficient. To estimate machining efficiency in terms of the content of charge per unit volume per unit of time in diamond cutting, “Charge Density (CD)” is proposed and examined as an evaluation criterion. The following are all discussed in detail: work frequency, work capacitance, wire-electrode number and short-circuiting percentage, heat-erosion on fins of different thicknesses, and fin efficiency.

Wire cut electrical discharge machining (WEDM) is a hybrid manufacturing technology which enables machining of all engineering materials. This research article deals with investigation on Optimization of the Process Parameters of the wire cut EDM of Bronze material of dimension (80*80*40) in mm. Material removal rate, Surface roughness and Kerf width were studied against the process parameters such as Pulse on time(TON), Pulse off time (TOFF) and Current(IP). The machining parameters for wire EDM were optimized for achieving the combined objectives. As there are three input parameters 27 experiments is carried out and full factorial is used. Optimized parameters were found using (ANOVA) and the error percentage can be validated and parameter contribution for the Material removal rate (MRR) and Surface roughness were found.

In electrical discharge machining, the formation of the modified surface layer depends on the physicochemical properties of the anode and cathode and the machining conditions. Experiments show that the mass transfer and coating thickness decrease with increase in thermal conductivity and decrease in melting point of the anode and cathode. The mass transfer and state of the modified surface are also impaired by increase in energy of the generator pulses and increase in roughness of the machined surface. These data are fundamental in selecting electrode materials and creating metal coatings with specified functional properties.

The paper investigates the influence of boron carbide powder (B4C) mixed in dielectric fluid on EDM of Inconel X-750 alloy. The process parameters selected as discharge current (Ip), pulse on time(Ton), pulse off time(Toff), boron carbide(B4C) powder concentration to examine their performance responses on Material Removal Rate (MRR), Surface Roughness(Ra) and Recast Layer Thickness (RLT).In this study, o examine the process parameters which influence the EDM process during machining of Inconel X-750 alloy using combined techniques of Taguchi and similarity to ideal solutions (TOPSIS).Analysis of variance (ANOVA) was conducted on multi-optimization technique of Taguchi-TOPSIS. ANOVA results identified the best process parameters and their percentages. It developed the mathematical equation on Taguchi-TOPSIS performance characteristics results. The multi optimization results indicated that Ip and Toff are more significant parameters; V, and Ton parameters are less significant. Finally, surface structures were studied at optimized EDM conditions by using scanning electron microscope (SEM).

In this study, the machinability of Boron Alloy Steel by electrical discharge machining (EDM) method was investigated. Taguchi L27 vertical knee test set was used in the experimental study. Discharge current, pulse on time, and pulse of time were selected as processing parameters. As a result of the experiments, average surface roughness, material removal rate, electrode wear rate values were investigated. The Taguchi method was used to decide on the optimal machining parameters. The effect of control factors on experimental results was calculated using analysis of variance. In the results of the experimental studies, the discharge current was found to be the most effective parameter on the electrode wear rate (EWR), average surface roughness (Ra) and material removal rate (MRR), It has been shown that increasing the discharge current (I) value will have a negative effect on Ra. The factors affecting the average surface roughness after calculation are 86.51% discharge current, 6.17% pulse on time and 0.2% pulse off time. It was concluded that the effects of the impact time and the impact waiting time on the average surface roughness were insignificant. For MRR, the discharge current is 75.56%, the pulse on time is 9.54%, and the pulse off time is 2.03%. For EWR, the discharge current is 52.87%, toff with 6.25%, and ton with 3.25%

Mathematical models are obtained for the temperature fields at the surface of a coated polymer tool electrode and a workpiece electrode in electrical discharge machining (EDM). In electrical discharge machining with a coated polymer tool electrode, the temperature distribution at the surface of the tool is nonuniform. That may disrupt the applied coating. Models of the temperature distribution within the workpiece at the instant of a single pulse are derived. Structural changes at the machined surface of the workpiece may be predicted.

Bu derleme çalışmada, seramiklerin talaşlı imalatında kullanılan alışılmamış imalat yöntemlerinin detaylı analizi yapılarak elde edilen kazanımlar ve eksiklerinin belirlenmesi amaçlanmıştır. Bu yöntemler arasında, aşındırıcı jet ile işleme ve aşındırıcı su jeti ile işleme, ultrasonik işleme ve döner ultrasonik işleme, elektro erozyon ve tel erozyon ile işleme en çok kullanılanlardır. Aşındırıcı jet ve aşındırıcı su jeti ile işleme diğer yöntemlere göre bazı üstün özelliklere sahip olması nedeni ile tercih sebebidir. Kesme bölgesinde çok az miktarda ısı üretmesi, metal, metal olmayan, kompozit, seramik gibi her türlü malzemenin kesilip işlenebilmesi, tel erozyon ile işleme işleminden daha yüksek bir malzeme çıkarma oranı ve lazer ile işleme işleminden daha iyi yüzey bütünlüğü sağlaması bu özelliklerden birkaçıdır. Ultrasonik ve döner ultrasonik işleme yöntemiyle, özellikle sert ve kırılgan malzemelerin hassas olarak işlenebilmesi ile diğer yöntemlere göre üstündür. Elektro erozyon ve tel erozyon ile işleme yönteminin tercih edilmesinin nedenleri, elektrik iletken her parça işlenebilmesi ve çok karmaşık şekillerde işleme sağlanabilmesi, takım ile iş parçası arasında temas olmadığı için fiziksel deformasyonun az olması, ısıl işlemden etkilenmiş bölgenin az olması olarak sıralanabilir. Gelecekteki araştırmalarda, talaş kaldırma hızı, yüzey kalitesi, enerji tüketimi ve işleme maliyetlerini içeren çok amaçlı optimizasyon çalışmalarına odaklanılması yüksek verimlilik ve sürdürülebilirlik noktasında önemli katkılar sağlayacaktır., In this review study, it is aimed to determine the gains and deficiencies obtained by making a detailed analysis of the unconventional manufacturing methods used in the machining of ceramics. The most used of these methods can be listed as abrasive jet machining and abrasive water jet machining, ultrasonic machining and rotary ultrasonic machining, electro erosion and wire erosion machining. Machining with abrasive jet and abrasive water jet is preferred with some superior features. Some of these features are that it generates very little heat in the cutting zone, can be cut and machined of all kinds of materials such as metal, non-metal, composite, ceramic, a higher material removal rate than wire erosion machining and better surface integrity than laser machining. With the ultrasonic and rotary ultrasonic processing method, it is superior to other methods, especially with the precision processing of hard and brittle materials. The reasons for choosing the electrical discharge machining and wire electrical discharge machining can be listed as the fact that every piece that conducts electricity can be processed, very complex shapes can be formed, physical deformation is less and the area affected by heat treatment is less since there is no contact between the tool and the workpiece. In future research, focusing on multi-purpose optimization studies including metal removal rate, surface quality and energy consumption and machining costs will make significant contributions to high productivity and sustainability.

Non-oriented electrical steel (NOES) laminations are commonly used to manufacture the rotor and stator core of electric machines. To achieve high machine efficiencies, it is desirable for these NOES laminations to be able to achieve a high saturation magnetisation whilst incurring minimal core losses. It is known that inappropriate machining of these laminations could cause significant deterioration in their magnetic properties. However, the mechanisms by which machining influences this deterioration are less understood. This study investigates the magnetic deterioration after four nonconventional machining methods: Abrasive Waterjet, Wire Electric Discharge Machining, Pulsed Laser, and Continuous Wave Laser. An in-depth investigation of surface integrity through a range of methods, i.e., surface topography, scanning electron microscopy (SEM), nanoindentation, electron backscatter diffraction (EBSD), and magnetic domain imaging, were conducted to study the mechanisms causing magnetic deterioration. The surface integrity after machining using conventional methods (e.g., microstructure and texture), was found to not be of high relevance unless this is combined with analysis on how machining affects the micro-magnetic domain structure. This paper, for the first time, highlights this aspect and attempts to make initial quantitative evaluations on how the magnetic domains are affected in the superficial layer that is the result of non-conventional machining.

Durable superhydrophobic aluminum alloy surfaces were prepared through a facile method: combining high-speed wire electrical discharge machining and chemical modification. Three types of pulse width were selected to machine the aluminum alloy surfaces with different levels of surface roughness. The effect of immersion time in perfluorooctanoic acid on the wettability of the aluminum alloy surfaces was examined. The contact angle of the superhydrophobic aluminum alloy surfaces was [Formula: see text], and the sliding angle was [Formula: see text]. After sanding with coarse sandpaper, the aluminum alloy surfaces still exhibited superhydrophobicity with a stroke of 450[Formula: see text]cm, indicating good mechanical durability. The prepared superhydrophobic aluminum alloy surface heated for 2[Formula: see text]h within the 190–240∘C temperature range showed favorable thermal stability. In addition, the superhydrophobic aluminum alloy surface exhibited self-cleaning property. Therefore, the superhydrophobic aluminum alloy surface prepared by using the simple mass production method showed good mechanical stability, thermal stability, and self-cleaning property, as well as broad application potential.

An emerging topic is electrical discharge (ED) coating with its application on complex shapes and cavities to repair components or act as functional coatings. Because it is a variant process of an electric discharge machine (EDM) with the ability to coat on electrically conductive substrates, there is a possibility that next-generation electrical discharge machining components may exploit the attachment phenomenon to enhance recast layer properties. Previously, researchers have obtained ED coating by mixing the powder in a dielectric medium and/or by using powder metallurgy electrodes. In this work, primarily, an insight in the formation of ED coating on-die sinks electrical discharge machine, using conventional electrode materials viz., bronze on titanium alloy (Ti-6Al-4V) is made. The bronze electrode on the titanium substrate obtained a crack-free copper coating of ~20 microns thickness. In order to perform the experiments, three combinations were made using five parameters: current (Amps), ton (µs), Toff (µs), duty cycle (%), and flushing pressure as constant (bar). After obtaining the coating, a combination of input parameters was selected by optimizing the output performance parameters, viz., the electrical discharge deposition rate, coating thickness, micro-cracks, and elemental coating composition. Secondarily, different optimization techniques viz., grey relational analysis, the technique for order of preferences by similarity to ideal solution, −nD angle method and information divergence method were implemented to find out the suitable combination of parameters where the latter two methods were introduced for the first time in this area of EDM optimization. A study was conducted to check whether the latter two methods are optimization techniques or multi-criteria decision-making techniques. The optimization of existing reactor types and the development of new reactors in wastewater treatment through EDC, by which energy could be saved by replacing the conventional techniques.

Possessing special wetting properties, superhydrophobic surfaces on 304 SS substrates have great application prospects in various fields. However, due to the excellent corrosion resistance of 304 SS, currently, only strong oxidants can directly process stainless steel to obtain desired structures, which poses great threats to human health and the environment. In addition, other methods, such as electrical discharge machining and coating, are relatively expensive, and the prepared surfaces tend to be fragile. Therefore, it is of great significance to find an environmentally friendly and highly efficient method to fabricate superhydrophobic surfaces on 304 SS substrates. Electrochemical etching can generate microstructures on metals with neutral electrolytes; nevertheless, there has been no report on fabricating superhydrophobic 304 SS surfaces by electrochemical etching with neutral electrolytes owing to the excellent corrosion resistance of 304 SS. In this paper, wire electrochemical etching with neutral sodium nitrate is adopted for the first time to fabricate superhydrophobic surfaces on 304 SS substrates. Based on theoretical analysis, superhydrophobic 304 SS surfaces with contact angles of ∼ 166° and roll-off angles of ∼ 10° are successfully fabricated. The prepared superhydrophobic 304 SS surfaces show excellent anti-icing performance and self-cleaning properties, which may greatly facilitate the application of 304 SS in extreme conditions.

Electrical discharge machining (EDM) is a non-conventional machining process, which is mostly used for machining of difficult-to-cut materials. These materials are often used in engineering applications that require improved surface properties; thus, surface modification is desirable in these cases. In the recent past, it has been observed that EDM is an alternative surface modification process due to migration of material from the electrode to the workpiece surface. Surface modification can be done with powder metallurgy (P/M) electrode as tool. The aim of this work is to examine the surface modification of the tool steel Calmax (Uddeholm) by EDM process using Cu-30 wt.% ZrO2 P/M green compact electrode. The influence of peak current (Ip) and pulse-on (Ton) on the Material Transfer Rate (MTR) and Surface Roughness (SR) was investigated and the surface characteristics were also evaluated by scanning electron microscopy (SEM). The experimental results confirm the material migration from the electrode to the machined surface and show that the higher MTR of 46.5 mgr/min is achieved on the combination of Ip = 9 A and Ton = 25 μs and the Ra varies from 3.72 μm to 7.12 μm.

The current time is characterized by the rapid development of modern production methods. These modern production methods are in many cases closely linked to progressive production methods, including EDM. The required high productivity and product quality is the reason for using such production methods. In addition to flawless production processes and highly sophisticated production equipment, these requirements can only be met using high-quality production tools. This paper, therefore, aims to describe the results of the analysis of current approaches in the field of modern trends in the development of electrical discharge machining, closely focusing on the development of control systems for generating electrical impulses in connection with the development of advanced tool electrodes. The performed analysis is also supplemented by the definition of mutual relations between selected properties of wire tool electrodes, their cutting power, and the achieved quality of the machined surface after electrical discharge machining. This should significantly help in increasing the quality level of the machined surface during wire electrical discharge machining and at the same time higher productivity of the electroerosive process. This will make this technology more competitive compared to other advanced technologies.

The objective of this work is to investigate the relationship between wettability and surface microgeometry of 6060 aluminum alloy created by electric discharge machining (EDM). The analyzes are enriched with the calculation of the correlation strengths between contact angles and geometric characteristics of surface topographies changing with the scale of observations. Surface topographies are measured by focus variation microscope and characterized with ISO parameters, geometric motifs and multiscale curvature tensor analysis. The wettability of the finished structures is investigated indirectly by contact angle measurements. The analysis were carried out using aqueous solutions of the semi-synthetic polymer, with different concentration and viscosity. The study showed that wetting behaviour of aluminum alloy can be easily controlled through appropriate EDM finishing.

In the electrical discharge machining (EDM) process, especially during the machining of hardened steels, changes in tool shape have been identified as one of the major problems. To understand the aforesaid dilemma, an initiative was undertaken through this experimental study. To assess the distortion in tool shape that occurs during the machining of EN31 tool steel, variations in tool shape were examined by monitoring the roundness of the tooltip before and after machining with a coordinate measuring machine. The change in out-of-roundness of the tooltip varied from 5.65 to 37.8 µm during machining under different experimental conditions. It was revealed that the input current, the pulse on time, and the pulse off time had most significant effect in terms of changes in the out-of-roundness values during machining. Machine learning techniques (decision tree, random forest, generalized linear model, and neural network) were applied for the prediction of changes in tool shape. It was observed that the results predicted by the random forest technique were more convincing. Subsequently, it was gathered from this examination that the usage of the random forest technique for the prediction of changes in tool shape yielded propitious outcomes, with high accuracy (93.67%), correlation (0.97), coefficient of determination (0.94), and mean absolute error (1.65 µm) values. Hence, it was inferred that the random forest technique provided better results in terms of the prediction of tool shape.