A Critical review on Artificial Intelligence in EDM: Advancements in Process Optimization, Monitoring, and Predictive Control

Authors

  • Azhar Equbal Jamia Millia Islamia image/svg+xml
  • Mohammad Zahid Ahmad
  • Mohammad Shahnawaz

DOI:

https://doi.org/10.37255/jme.v21i1pp001-005

Keywords:

Electrical Discharge Machining, Artificial Intelligence, Machine Learning, Neural Networks, Fuzzy Logic, Parameter Optimization

Abstract

Electrical Discharge Machining (EDM) is a widely used non-traditional machining process that removes material from a workpiece by a series of repetitive discharges. EDM is widely used for machining hard, brittle, and heat-resistant materials, often achieving high precision. The EDM process is influenced by various factors, including discharge energy, pulse duration, and electrode wear. These factors can be challenging to optimize due to their interdependencies and the highly nonlinear behaviour of the process. Traditionally, the optimization process has been conducted through trial and error or operator expertise, both of which are time-consuming and costly. Artificial Intelligence (AI), including machine learning (ML), neural networks (NN), fuzzy logic, and real-time process monitoring, offers powerful tools to automate and optimize these processes. This paper explores how AI is applied in EDM for process optimization, quality enhancement, predictive modeling, and real-time adjustments, with a focus on practical applications, methodologies, and challenges.

Downloads

Download data is not yet available.

Author Biography

  • Azhar Equbal, Jamia Millia Islamia

    Faculty of Engineering and Technology, Department of Mechanical Engineering, Jamia Millia Islamia, New Delhi - 110025, India

References

1. Equbal, A.K. Sood. Electrical discharge machining: an overview on various areas of research, Manuf. Ind. Eng. 13 (2014) 1-6.

2. Equbal, M. I. Equbal, A.K. Sood, An investigation on the feasibility of fused deposition modelling process in EDM electrode manufacturing, CIRP J Manuf. Sci. Technol. 26 (2019) 10-25.

3. S. P. Gounder, S. Tamil, S. Vartharajan, R. Venkatesan. Study of microEDM parameters of Stainless Steel 316L: Material Removal Rate Optimization using Genetic Algorithm, International Journal of Engineering and Technology. 6(2) (2014) 1065-1071.

4. R. Singh, A. Dvivedi, P. Kumar. EDM of high aspect ratio micro-holes on Ti-6Al-4V alloy by synchronizing energy interactions, Mater. Manuf. Process. 35 (2020) 1188-1203.

5. Equbal, A. Equbal, Z. A Khan, I. A. Badruddin et al. Investigating the dimensional accuracy of the cavity produced by ABS P400 polymer-based novel EDM electrode, Polymers. 13 (2021) 4109.

6. W. Ming, H. Jia, H. Zhang, Z. Zhang, K. Liu, J. Du, F. Shen, G. Zhang. A comprehensive review of electric discharge machining of advanced ceramics, Ceramics International. 46, (2020) 21813-21838.

7. K. Ishfaq, M. Sana, W. M. Ashraf. Artificial intelligence–built analysis framework for the manufacturing sector: performance optimization of wire electric discharge machining system, The International Journal of Advanced Manufacturing Technology. 128 (2023) 5025–5039.

8. U. M. R. Paturi, S. Cheruku, V. P. K. Pasunuri et al. Machine learning and statistical approach in modeling and optimization of surface roughness in wire electrical discharge machining, Mach Learn Appl. 6 (2021)100099.

9. S. B. Ubale, S. D. Deshmukh, S. Ghosh. Artificial Neural Network based Modelling of Wire Electrical Discharge Machining on Tungsten-Copper Composite, Materials today: Proceedings. 5/2 (2018) 5655-5663.

10. P. S. Bharti. Two-step optimization of electric discharge machining using neural network based approach and TOPSIS, Interdisciplinary Applications for Sustainability. 23 (2020) 81-96.

11. Equbal, S. Akhter, M. A. Equbal, A. K. Sood. Application of Machine Learning in Fused Deposition Modeling: A Review, Fused Deposition Modeling Based 3D Printing. 4/1 (2021) 445-463.

12. V. S. Jatti, R. B. Dhabale, A. Mishra, N. K. Khedkar, V. S. Jatti, A. V. Jatti. Machine Learning Based Predictive Modeling of Electrical Discharge Machining of Cryo-Treated NiTi, NiCu and BeCu Alloys, Applied system Innovation. 5/6 (2022), 107.

13. B Pradhan, B. Bhattacharyya. Modelling of micro-electrodischarge machining during machining of titanium alloy Ti—6Al—4V using response surface methodology and artificial neural network algorithm, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 223/6 (2009), 683-693.

14. Kao, A. Shih, S. F. Miller. Fuzzy Logic Control of Microhole Electrical Discharge Machining, Journal of Manufacturing Science and Engineering. 130/6 (2008) 064502.

15. R. Munaro, A. Attanasio, A. D. Prete. Tool Wear Monitoring with Artificial Intelligence Methods: A Review, Journal of manufacturing and material processing. 7/4, (2023) 129.

Downloads

Published

2026-03-01

Issue

Section

Articles

How to Cite

[1]
“A Critical review on Artificial Intelligence in EDM: Advancements in Process Optimization, Monitoring, and Predictive Control”, JME, vol. 21, no. 1, pp. 001–005, Mar. 2026, doi: 10.37255/jme.v21i1pp001-005.

Similar Articles

11-20 of 276

You may also start an advanced similarity search for this article.

Most read articles by the same author(s)