Environmental impact, personnel health and operational safety aspects of electric discharge machining: A review

Electrical discharge machining has emerged as the most popular non-conventional material removal process due to its novel variants, inherent process capability, and suitability for hybridization with other conventional and non-conventional material removal processes. However, high specific energy consumption, self-sacrificial electrode, hazardous emissions, toxic dielectric waste and sludge generation make this process one of the most unsustainable machining processes. Increased market competitiveness and requirement to comply with ISO 14000 standards demanded to implement sustainable manufacturing practices for short- and long-term business growth. In this article, the authors have reviewed the research work done in three of the sustainability indicators for the electrical discharge machining process, such as environmental impact, personnel health and operational safety. Modes of dielectric supply such as wet, dry and near dry have a paramount influence on the said sustainability indicators. Research works related to each indicator have been reviewed for the three modes of dielectric supply. This review provides a basis for understanding the current status of research activities for electrical discharge machining in the context of sustainability indicators. Future research needs have been discussed to make electrical discharge machining a more sustainable metal removal process.