Modeling, Simulation and Optimization Techniques in Electrical Discharge Machining: A Comprehensive Review

Electrical Discharge Machining (EDM) is a non-conventional metal removal process which is widely used for shaping hard materials and complex geometries. The EDM process has become more predictable and controllable due to the advancements in numerical simulation and thermo-physical modeling. The modeling approaches described in recent literature, such as thermalelectrical models, FEM simulations, plasma flushing efficiency models and intelligent frameworks combining Artificial NeuralNetworks (ANN) and Genetic Algorithms (GA), are compiled and critically examined in this review paper. Crater formation, material removal rate (MRR), tool wear, thermal stress and plasma behaviour are all discussed in the paper. The use of different modeling techniques for predicting intricate EDM responses and optimize machining performance is also emphasized.