The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al₂O₃), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al₂O₃ leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al₂O₃ ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.

This study investigated the machining characteristics of two shapes of diamond grit – coated tools used in grinding-aided electrochemical discharge machining for optical glass drilling. The effects of roundness, machining accuracy, surface roughness, and tool wear under various machining depths and electrode rotating speeds were explored, and the bubble generation mechanism and its effects on the discharge current waveform and electrochemical discharge reaction were observed. This study revealed that the bubbles generated in the gaps between diamond particles combine with each other to form a stable bubble film. Owing to differences in bubble generation mechanisms, the discharging waveform of the diamond grit – coated tool was more stable than that of tools without diamond grit – coated. It is known from the experimental results that the diamond grit – coated ball end mill in this method minimized shape roundness errors, machining time and the fracture of the exit edge.

This research explores the efficiency of Electrical Discharge Coating (EDC) as an advanced surface modification technique using powder suspension, conventional electrodes, and 3D printed electrodes (3DPE), focusing on Ti6Al4V alloys. Conventional Ti electrodes resulted in 100% titanium content with a thickness of 110 µm, while the powder suspension coating was inadequate. The use of 3D printed electrodes showed promising results, with uniform deposition of 61.20 µm thickness and enhanced surface properties under 10 A current. Further analysis of 3D printed Ti6Al4V EDC revealed a higher Ti percentage of 44.20%, TiC formation of 84.17%, and enhanced microhardness with lower surface roughness. Thorough optimization of 3D printed electrode EDC has been undertaken. The study suggests the potential replacement of traditional electrodes such as powder metallurgy with 3D printed counterparts, advancing surface modification techniques and opening new avenues for materials engineering and manufacturing processes.

In this research, the main purpose was to study the applicability of a machining method on microscale medical-equipment manufacturing. The characteristics of wire electrochemical micromachining (WECMM) against NiTi 50-50 wire was investigated. The study utilized a tungsten wire 0.03 mm in diameter as an electrode to cut a fine slot into the nickel–titanium wire. In order to reach a high-precision WECMM finish, an ultrashort pulse power generator was used as a power source to minimize the stray current effect, thus improving the machining accuracy. During the process, various machining parameters were tested for their effects on machining characteristics. In addition, ultrasonic-vibration-aided WECMM was investigated to determine whether it benefited the machining characteristics. The experiment’s results showed that under such an experiment setting, microslots can be successfully manufactured. Furthermore, with the advance adjustment of experimental parameters, the machining accuracy was improved. Finally, a fine slot was manufactured under the optimum experiment parameters and aided by ultrasonic vibration.

The micro-hole machining of quartz wafers depends on photolithography techniques akin to those used in semiconductor fabrication. These methods present challenges due to high equipment setup costs, large space requirements, and environmental pollution risks. This research applies ultrasonic vibration assistance in electrochemical discharge machining to create an array of micro-holes on quartz wafers. In the experiments, a self-prepared tungsten carbide micro-electrode array served as the tool electrode. This electrode was a 2 × 2 square array, with needles measuring 30 × 30 μm. A series of experiments was conducted to investigate the effects of various machining parameters, including working voltage, feed rate, duration time, duty factor, and ultrasonic power level, on the characteristics of the micro-hole array. The characteristics included average hole diameter and through-hole surface morphology. The experimental objective was to achieve a through-hole diameter of 80 μm with an accuracy of ±8 μm. During the electrochemical discharge machining, suitable ultrasonic vibrations can thin the insulating gas film coating on the electrode surface, resulting in a more uniform gas film. As the insulating gas film’s thickness decreased, so did the critical voltage needed for the electrochemical discharge machining, reducing the hole’s diameter expansion. The ultrasonic vibration assistance can enable the satisfaction of the dimensional accuracy requirement. The experimental results indicate that ultrasonic vibration assistance can effectively improve the processing capacity and reduce sample fragmentation. A working voltage of 44 V, feed rate of 1 μm/6 s, duration time of 30 μs, duty factor of 30%, and ultrasonic power level of 1 resulted in better inlet and outlet surface morphology without outlet fragmentation. Moreover, the average diameters of the inlet and outlet were roughly 80 μm while meeting the through-hole diameter of 80 μm with accuracy of ±8 μm.