The present study reviews the state-of-the-art mechanism for the generation of spark by means of micro-electrochemical discharge machining (µ-ECDM) process. It also describes various electrical and non-electrical parameters, influencing performance of the machining process. In the process, several variants of µ-ECDM process have been outlined which were developed with technological advancements for enhanced performance. The review also makes an in-depth study on advancement of micro- and nano-size tool manufacturing processes by unconventional machining techniques. Finally, it sums up potential of this process for development of various hybrid machining processes to achieve better performance.

In this experimental study, the effects of major laser process control parameters, such as the laser power, beam scanning speed and assisting gas flow rate, on cut surface integrity defined by the kerf width, taper percentage, and the extent of heat affected zone (HAZ) were investigated. Response surface methodology (RSM) along with central composite design (CCD) of the experiment was used to optimize the process parameters to get better-cut surface quality. The optimum values of process parameters corresponding to cut surface with minimum defects are laser power 260 W, cutting speed 4500 mm per min, and assistance gas flow rate 14.23 l/min and the corresponding kerf width, taper percentage, and the width of HAZ are found to be 163.7 µm, 5.75%, and 573.28 µm. The confirmation experiments have been conducted that provide favorable results with an error of 2.70%, 1.87%, and 0.36%, for kerf width, taper percentage, and width of HAZ, respectively.