Electrochemical discharge machining (ECDM) is a triumphant process for producing micro-holes in glass materials and yet holds the potential for improvement. In ECDM, electrolyte selection is crucial as it controls the spark pattern and flushes debris from the machining zone. Despite numerous experimental studies, few analytical studies were reported for ECDM modeling and finite element modeling-based electrolyte’s comparative study is not reported yet. This study focuses on developing a thermal model to compare the ECDM performance in terms of material removal rate (MRR) for different electrolytes, viz. NaOH, KOH, and NaCl. The plots of temperature distributions are obtained underneath the spark and further processed to evaluate the MRR. Predicted results are observed to be in accordance with the experimental results. The effects of electrolyte concentration, applied voltage, spark radius, and duty ratio on MRR are analyzed through simulations. Results show that MRR decreases with the increase in spark radius while increases with the increase in other parameters. NaOH electrolyte produces higher MRR; an increase of 8.72 mg and 10.18 mg is observed when compared to KOH and NaCl at 60 wt% concentration. Moreover, experimental studies are performed to evaluate the electrolyte’s effect (includes NaNO₃) on radial overcut (ROC) and hole circularity. KOH electrolyte provides the least overcut and better hole circularity due to stable and smooth spark pattern. An improvement of 32.1% in overcut and 40.8% in hole circularity was observed using the KOH when compared to NaNO₃. NaOH and KOH are revealed as the successful electrolytes for machining with ECDM.

电化学放电加工（ECDM）是在玻璃材料上产生微孔的成功方法，但仍有改进的潜力。在ECDM中，电解液的选择至关重要，因为它可以控制火花图案并冲洗加工区的碎屑。尽管进行了大量实验研究，但很少有关于ECDM建模的分析研究的报道，基于有限元建模的电解质的比较研究尚未见报道。这项研究的重点是开发一个热模型，以比较ECDM在不同电解质的材料去除率（MRR）方面的性能。NaOH，KOH和NaCl。在火花下方获得温度分布图，并进行进一步处理以评估MRR。观察到的预测结果与实验结果一致。通过仿真分析了电解质浓度，施加电压，火花半径和占空比对MRR的影响。结果表明，MRR随着火花半径的增加而减小，而随着其他参数的增加而增加。NaOH电解质产生更高的MRR；与浓度为60 wt％的KOH和NaCl相比，观察到增加了8.72 mg和10.18 mg。此外，还进行了实验研究以评估电解质的作用（包括NaNO₃）径向过切（ROC）和孔的圆度。由于稳定且光滑的火花图案，KOH电解质可提供最少的过切和更好的孔圆度。与NaNO ₃相比，使用KOH观察到过切率提高了32.1％，孔圆度提高了40.8％。NaOH和KOH是成功用于ECDM加工的电解质。