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Micromachines
Special Issues
Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications, 4th Edition
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Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications, 4th Edition

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D：Materials and Processing".

Deadline for manuscript submissions: closed (30 June 2025) | Viewed by 3252

Special Issue Editors

Dr. Irene Fassi

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council (STIIMA-CNR), 13900 Bari, Italy
Interests: micro manufacturing; micro robotics; micro assembly; micro EDM; micro injection molding
Special Issues, Collections and Topics in MDPI journals
Dr. Francesco Modica

E-Mail Website
Guest Editor
Institute of Intelligent Industrial Technologies and Systems for Advanced Manufacturing, National Research Council, 70124 Bari, Italy
Interests: micro EDM; micro manufacturing; additive manufacturing; virtual prototyping
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Micro Electrical Discharge Machining (micro-EDM) is a thermo-electric and contactless process that is most suited to micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed. Among the various micro-machining processes, micro-EDM is known to have many industrial applications, such ashigh-aspect-ratio micro holes for fuel injectors, high-precision moulds, and biomedical components. The main issues restricting the application of micro-EDM involve handling and fixturing, electrode and workpiece preparation, process parameter optimization, the identification and minimization of sources of errors as tool wear, and measurement issues.

In the recent past, numerous EDM systems were developed to perform micro- and nano-scale EDM. These systems use newer control strategies and optimization methodologies to perform the EDM processes.

This Special Issue pursues contributions (research papers, communications, and review articles) that focus on recent developments in micro-EDM machining. Topics of interest include, but are not limited to, the following:

  • Process mechanism modeling and simulation;
  • Process monitoring and control;
  • Parameters optimization;
  • Tool wear management;
  • Novel machine concept;
  • New material processing;
  • Dielectrics;
  • High-aspect-ratio features and surface texturing;
  • Hybrid machining;
  • New application of micro-EDM process.

We look forward to receiving your submissions.

Dr. Irene Fassi
Dr. Francesco Modica
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2100 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • micro EDM
  • parameters optimization
  • process simulation
  • tool wear
  • difficult-to-cut material

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Related Special Issues

Published Papers (2 papers)

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Research

25 pages, 11507 KiB  
Article
Accurate EDM Calibration of a Digital Twin for a Seven-Axis Robotic EDM System and 3D Offline Cutting Path
by Sergio Tadeu de Almeida, John P. T. Mo, Cees Bil, Songlin Ding and Chi-Tsun Cheng
Micromachines 2025, 16(8), 892; https://doi.org/10.3390/mi16080892 - 31 Jul 2025
Viewed by 265
Abstract
The increasing utilization of hard-to-cut materials in high-performance sectors such as aerospace and defense has pushed manufacturing systems to be flexible in processing large workpieces with a wide range of materials while also delivering high precision. Recent studies have highlighted the potential of [...] Read more.
The increasing utilization of hard-to-cut materials in high-performance sectors such as aerospace and defense has pushed manufacturing systems to be flexible in processing large workpieces with a wide range of materials while also delivering high precision. Recent studies have highlighted the potential of integrating industrial robots (IRs) with electric discharge machining (EDM) to create a non-contact, low-force manufacturing platform, particularly suited for the accurate machining of hard-to-cut materials into complex and large-scale monolithic components. In response to this potential, a novel robotic EDM system has been developed. However, the manual programming and control of such a convoluted system present a significant challenge, often leading to inefficiencies and increased error rates, creating a scenario where the EDM process becomes unfeasible. To enhance the industrial applicability of this robotic EDM technology, this study focuses on a novel methodology to develop and validate a digital twin (DT) of the physical robotic EDM system. The digital twin functions as a virtual experimental environment for tool motion, effectively addressing the challenges posed by collisions and kinematic singularities inherent in the physical system, yet with proven 20-micron EDM gap accuracy. Furthermore, it facilitates a CNC-like, user-friendly offline programming framework for robotic EDM cutting path generation. Full article
(This article belongs to the Special Issue Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications, 4th Edition)
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20 pages, 3907 KiB  
Article
Experimental Investigation of Al2O3 Nano-Powder-Mixed Dielectric in EDM-Assisted Micro-Milling
by Sharad Yadav, Deepak Agarwal, Anuj Kumar Sharma, Rabesh Kumar Singh, Saurabh Chauhan and Shalini Mohanty
Micromachines 2025, 16(7), 725; https://doi.org/10.3390/mi16070725 - 21 Jun 2025
Viewed by 2486
Abstract
This paper investigates the use of Al2O3 nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micro-channel fabrication performance in terms of TWR, [...] Read more.
This paper investigates the use of Al2O3 nano-powder-stirred micro-EDM process for generating micro-channels. This study focuses on the effect of critical machining process parameters, such as capacitance levels and nano-powder concentration, on the micro-channel fabrication performance in terms of TWR, MRR, depth, and width. A two-stage nested ANOVA is employed to understand the effect of powder concentration within different capacitance levels. The results show that the powder concentration significantly influences the system’s performance in conjunction with the capacitance. At low (100 pF) and high (1000 pF) capacitance, the addition of Al2O3 nano-powder increases the MRR, depth, and width but decreases TWR up to a concentration of 1.0 g/L. A desirability function analysis (DFA) tool identified the best overall performance from 14 experiments, revealing that 100 pF and 1 g/L yield the optimal outcomes. Full article
(This article belongs to the Special Issue Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications, 4th Edition)
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