OBRABOTKAMETALLOV Vol. 27 No. 4 2025 173 EQUIPMENT. INSTRUMENTS Modern methods of manufacturing of complex-profi le electrode-tools for electrical discharge machining: a literature review Timur Ablyaz a , Ilya Osinnikov b, Evgeniy Shlykov c, *, Karim Muratov d, Vladimir Blokhin e Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation a https://orcid.org/0000-0001-6607-4692, lowrider11-13-11@mail.ru; b https://orcid.org/0009-0006-4478-3803, ilyuhaosinnikov@bk.ru; c https://orcid.org/0000-0001-8076-0509, Kruspert@mail.ru; d https://orcid.org/0000-0001-7612-8025, Karimur_80@mail.ru; e https://orcid.org/0009-0009-2693-6580, warkk98@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2025 vol. 27 no. 4 pp. 148–179 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.4-148-179 ART I CLE I NFO Article history: Received: 11 June 2025 Revised: 04 July 2025 Accepted: 09 September 2025 Available online: 15 December 2025 Keywords: Experimental production Electrical discharge machining Tool electrode Tool electrode confi guration Fabrication methods Additive methods Rapid prototyping technologies Investment casting Powder metallurgy ABSTRACT Introduction. Pilot production plays an important role in modern mechanical engineering. Copy-piercing electrical discharge machining (CPEDM) technology has become widespread in machining pilot parts manufactured in fl exible production fl ows. Manufacturing tool-electrodes (TE) is one of the main stages of the CPEDM technological cycle. Purpose of the work. Review of existing studies of modern methods of manufacturing toolelectrodes for electrical discharge machining. Research methods. A literature review of studies in the fi eld of electrical discharge machining devoted to tool-electrodes, carried out mainly over the past 20 years, is presented. Various confi gurations of structural elements machined using CPEDM technology, as well as TE confi gurations for their machining, are described. The dependences of the infl uence of the geometric parameters of the simplest TE confi gurations on the output parameters of CPEDM are shown. The main groups of TE manufacturing methods are identifi ed. The limitations, advantages, and disadvantages of alternative methods to traditional ones are described. The main trends in the development of modern TE manufacturing methods are revealed. Results and discussion. Based on the literature review of modern research in the fi eld of electrical discharge machining, current trends in the development of tool-electrode confi gurations are presented, and problems in the manufacture of complexshaped tool-electrodes using traditional methods are identifi ed. It has been established that among the alternative methods for manufacturing tool-electrodes, investment casting, powder metallurgy, and additive methods are of greatest interest to modern scientists. It has been shown that each method has its own advantages and disadvantages, confi rmed by a number of studies. The following current areas of development of complex-shaped tool-electrodes and methods for their manufacture are highlighted: topological optimization of tool-electrodes, use of modern high-tech casting methods; expansion of the range of tool-electrodes materials with improved electrical discharge properties; optimization of powder metallurgy modes, FDM printing, and selective laser melting; increasing the thickness and quality of tool-electrodes coatings obtained using rapid prototyping technologies. For citation: Ablyaz T.R., Osinnikov I.V., Shlykov E.S., Muratov K.R., Blokhin V.B. Modern methods of manufacturing of complex-profi le electrode-tools for electrical discharge machining: a literature review. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 4, pp. 148–179. DOI: 10.17212/1994-6309-2025-27.4-148-179. (In Russian). ______ * Corresponding author Shlykov Evgeniy S., Ph.D. (Engineering), Associate Professor Perm National Research Polytechnic University, 29 Komsomolsky prospekt, 614990, Perm, Russian Federation Tel.: +7 961 759-88-49, e-mail: Kruspert@mail.ru References 1. Egorova A.O. Konkurentnye strategii predpriyatii mashinostroeniya: sovremennaya rossiiskaya praktika [Mechanical engineering enterprises’ competitive strategies: present-day Russian practice]. Sovremennye naukoemkie tekhnologii. Regional’noe prilozhenie = Modern High Technologies. Regional Application, 2013, no. 2 (34), pp. 45–51. 2. Gunina I.A., Savich Y.A. K voprosu o problemakh povysheniya konkurentosposobnosti mashinostroitel’nykh predpriyatii [The questions about the problems of increase of the competitiveness of machine-building enterprise]. Vestnik Voronezhskogo gosudarstvennogo tekhnicheskogo universiteta = Bulletin of the Voronezh State Technical University, 2017, vol. 13, no. 2, pp. 136–140.
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