Advancements in electrical discharge machining of AMCs: a review of modeling approaches, optimization strategies and sustainability trends

Research on aluminum-based metal matrix composites (AMCs) has increased due to the demand in various fields such as aerospace, automotive and defence industries for lightweight and high strength materials. But hard ceramic reinforcements in AMCs pose a number of challenges to the conventional machining process. Electrical Discharge Machining (EDM) is emerging as one of the viable options that can easily deal with the intrinsic hardness and brittleness of AMCs. This review is a comprehensive research perspective of the recent developments in application of EDM in AMCs. It critically reviews modeling strategies from conventional empirical approaches to hybrid and machine learning algorithms to predict machining responses. These algorithms could help to improve important performance parameters such as material removal rate, tool wear and surface finish. The article also reviews the recent developments in the application of sustainable EDM methods, such as the development of eco-friendly dielectrics and energy saving in the EDM process. This integrated assessment analyzes the current gaps and outlines the rising problems and future research initiatives such as the integration of digital twin and hybrid EDM technologies. This work provides valuable insights for the researchers to further develop the scientific understanding and application of the EDM for AMC machining.