• cryogenic treatment
• dielectric fluid
• Electrical discharge machining
• electrode design
• flushing method
• machined surface roughness
• material removal rate

Electrical Discharge Machining (EDM) process is broadly utilized in industries for machining hard-to-cut materials and producing complex shapes with high precision. However, EDM faces significant challenges and drawbacks related to machining performance, including and not limited to low material removal rates MRR, high tool wear rate TWR, and surface roughness SR, as well as environmental concerns such as toxic gas emissions and health risks. Although previous studies have been focused on improve EDM last decades, still there remains a need to systematically address the most trend technologies that shall mitigate these drawbacks. Thus, this thesis initially addresses the gap of machining process performance through reviewing and classifying these technologies into four main drivers: dielectric fluids, hybrid processes, electrode tools, and control methods. The maturity of each technology is assessed using technology readiness levels TRL, ensuring practical relevance for industrial applications. So, this thesis goes in detail on technologies related to dielectric fluid and electrode drivers due to its significant impact on the EDM process performance. In contrast, hybrid process and control (acoustic monitoring) serve as additional drivers. For the first driver (dielectric fluid), we explore two approaches: powder mixed dielectric fluid technology (PMEDM) for enhancing EDM machining performance and biodiesel dielectric fluid for addressing environmental considerations. On a hand, we select the graphene powder to be mixed with the dielectric fluid due to its thermal and electrical properties compared to other powder types. We conduct several experiments using various concentrations of graphene powder under aggressive electrical EDM parameters to evaluate its effects under real EDM process conditions. On the other hand, a new type of vegetable-based oil (corn biodiesel) is synthesized through the transesterification of corn oil. We evaluate the feasibility of corn biodiesel as a dielectric fluid for enhancing the EDM performance while aligning with its green environmental impact. The evaluation of corn biodiesel is conducted in comparison with synthetic oil and traditional dielectric fluids (transformer oil and kerosene). The findings from both approaches involving dielectric fluids revealed significant improvements in machined surface quality. Additionally, corn biodiesel demonstrates lower TWR compared to traditional fluids and achieved faster machining times than synthetic oil. In term of the electrode driver, the research focuses on three directions: cryogenically treated electrodes, coated electrodes, and the design of new electrode. Regarding the first technology (cryogenic treatment), the research handles its effects on graphite electrode material, because most of studies have investigated its impact on metallic materials. Our work specifically examines the influence of deep cryogenic treatment on standard and high-quality graphite electrodes with various temperature, worming rate, and soaking time. While the second direction, coated electrodes, this work investigates the impact of graphene and graphene/zirconium coatings on graphite electrodes with various electrical parameters for implementing finishing and roughing EDM processes. Additionally, the third direction investigates the possibility of designing a new electrode. A new U-shaped frame electrode is being developed and optimized to enhance the EDM machining procedure. The findings from the electrode driver technologies demonstrate improvements in EDM performance under real industrial conditions, aligning with environmental impact and the goals of the green industrial movement. Overall, this thesis discusses the impact of main drivers, technology trends, and its applicability on the EDM process through conducting different practical experiments highlighting the current challenges, limitations and promising results.