Micromachining through Ultrasonic-Assisted Electrochemical Discharge Process: A Review

<div>As demand for microcomponents has escalated in diverse areas of automotive, medicine, communications, electronics, optics, biotechnology, and avionics industries, there is a need for hybrid manufacturing techniques that can effectively micromachine hard and brittle materials. Electrochemical discharge machining (ECDM) is an advanced manufacturing process for machining difficult-to-cut materials. With a need for precision and accuracy, tool kinematics is a potential research area in ECDM for achieving geometrical dimensioning and tolerances (GD&T). Therefore, the present study reviews the ultrasonic vibration–assisted ECDM (UA-ECDM) hybrid process and the performance of its process parameters (voltage, electrolyte type and its concentration, electrode material, pulse duration, and amplitude) on the material removal rate (MRR), tool electrode wear (TEW), surface integrity, and difficult-to-cut materials. Also, the present work mentions current problems (debris and bubbles trapped, electrolyte circulation, and gas film formation) faced and future research directions to increase the process capabilities based on published research in the UA-ECDM process.</div>