Open Access
Review
Electrical Discharge Machining of Composites: A Critical Review of Challenges and Innovations
André F. V. Pedroso1, 2, *
, Rafael Lucas1, 3
, Luís Teixeira1
, Raul D. S. G. Campilho1, 4
, Arnaldo G. Pinto1
, Rúben D. F. S. Costa2, 4
, Rita de Cássia Mendonça Sales-Contini1, 5
Author Information
Submitted: 5 May 2025 | Revised: 20 May 2025 | Accepted: 28 May 2025 | Published: 16 Jun 2025
Abstract
Electrical Discharge Machining (EDM) is a critical non-conventional manufacturing technique for shaping electrically conductive materials, especially those with high hardness or complex geometries. Utilising thermal energy generated by controlled electrical discharges, EDM enables precise material removal without mechanical contact. This review systematically examines recent advancements in EDM with a focused lens on composite materials, specifically Metal-Matrix Composites (MMCs), Polymer-Matrix Composites (PMCs), and Ceramic-Matrix Composites (CMCs), which present distinct challenges due to their heterogeneous structure and limited machinability using conventional methods. This study investigates the influence of both electrical and non-electrical parameters on key performance indicators, including Material Removal Rate (MRR), Tool Wear Rate (TWR), and surface integrity. Notably, hybrid approaches such as Powder-Mixed EDM and cryogenic-assisted EDM demonstrate significant potential in enhancing machining performance and extending Tool Life (TL). By synthesising over two decades of research, this review identifies critical trends, technological innovations, and ongoing challenges in the EDM of composites. The findings emphasise the importance of parameter optimisation and novel dielectric modifications in advancing the efficiency, precision, and sustainability of EDM processes. This work provides a timely and comprehensive perspective on the evolving landscape of composite machining, outlining directions for future research in adaptive and hybrid EDM technologies.
Keywords
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Issue
Volume 1, Issue 1How to Cite
Pedroso, A. F. V., Lucas, R., Teixeira, L., Campilho, R. D. S. G., Pinto, A. G., Costa, R. D. F. S., & Sales-Contini, R. d. C. M. (2025). Electrical Discharge Machining of Composites: A Critical Review of Challenges and Innovations. Journal of Mechanical Engineering and Manufacturing, 1(1), 5. https://doi.org/10.53941/jmem.2025.100005
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