Abstract Electrochemical discharge machining (ECDM) process is prominent machining process for processing of composites, glass, ceramics, and super-alloys. In the recent years, the ECDM process has attained popularity due to its applicability to generate micro-holes, micro-channels on different materials irrespective to their properties. This study presents the various environmental aspects of ECDM process for its transformation to sustainable and green manufacturing. The exhaustive analysis of fume particles generated in ECDM process with their characterization and health impacts has been attempted in the present work. A detailed procedure has been reported to explore the effect of applied voltage and electrolyte concentration on fume mass concentration, fume particles size, particle morphologies, and chemical composition. The morphology of fume particles revealed presence of spherical, irregular, rectangular, and agglomerations shapes. The chemical composition of fume particles indicates presence of metallic toxic and carcinogen elements such as Al, Fe, Cr, Cu, Ti, Ni, etc. The presence of hazardous compounds in the breathing zone was studied using Fourier transform infrared spectroscopy analysis of breathing air. Additionally, occupational risks associated with fumes emission and their control measure has been addressed in this research work.

中文翻译：

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可持续电化学放电加工工艺：排放产品的表征和操作员的职业风险

摘要 电化学放电加工（ECDM）工艺是加工复合材料、玻璃、陶瓷和高温合金的主要加工工艺。近年来，ECDM 工艺因其适用于在不同材料上产生微孔、微通道而不受其性能影响而广受欢迎。本研究介绍了 ECDM 过程向可持续和绿色制造转型的各个环境方面。目前的工作已尝试对 ECDM 过程中产生的烟尘颗粒及其特征和健康影响进行详尽分析。已经报道了一个详细的程序来探索施加的电压和电解质浓度对烟雾质量浓度、烟雾颗粒大小、颗粒形态和化学成分的影响。烟雾颗粒的形态显示存在球形、不规则、矩形和团块形状。烟雾颗粒的化学成分表明存在金属有毒和致癌元素，如 Al、Fe、Cr、Cu、Ti、Ni 等。 使用傅里叶变换红外光谱分析呼吸空气研究呼吸区中有害化合物的存在. 此外，本研究工作还涉及与烟雾排放相关的职业风险及其控制措施。使用傅立叶变换红外光谱分析呼吸空气来研究呼吸区中有害化合物的存在。此外，本研究工作还涉及与烟雾排放相关的职业风险及其控制措施。使用傅立叶变换红外光谱分析呼吸空气来研究呼吸区中有害化合物的存在。此外，本研究工作还涉及与烟雾排放相关的职业风险及其控制措施。