Management of Electrochemical Machining: A Review of Process Parameters, Operations, and Recent Developments

Electrochemical machining (ECM) is a controlled anodic dissolution method used in industries such as aerospace, automotive, and health care for precise metal shaping. It offers advantages including improved surface quality, enhanced
corrosion resistance, and extended tool (cathode electrode) lifespan. This study reviews key aspects of ECM management for various metals, focusing on workpiece material, sodium chloride and sodium nitrate electrolytes, process duration, workpiece surface quality, and temperature influence on material removal rates. Additionally, this paper introduces recent advances in various electrochemical machining techniques, including electrochemical finishing, air-shielding
electrochemical micromachining (AS-EMM), electrochemical laser jet machining (LAJECM), wire electrochemical machining (wire ECM), counter-rotating electrochemical machining (CRECM), and vision-assisted constant-IEG electrochemical
machining (VACGECM), all of which emphasize the development and management of these processes. Therefore, in this study we discuss the factors that challenge the scale-up of ECM. Several barriers, including the absence of credible models to forecast material removal rates, corrosion control, removal of hydrogen gas, and scale-up issues such as maintaining current density, effective electrolyte management, and developing environmentally sustainable alternative electrolytes, have been identified. These are barriers that must be addressed before a successful transition to commercialization. The study emphasizes the need for continuous innovation in ECM technology to improve efficiency, sustainability, and scalability while addressing challenges related to electrolyte management and sustainability.