An environment-friendly and sustainable machining method: near-dry EDM

Dhakar, Krishnakant; Chaudhary, Kuldeep; Dvivedi, Akshay; Bembalge, O.B.

doi:10.1080/10426914.2019.1643471

Cited by 67 publications

(21 citation statements)

References 15 publications

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“…On the other hand, sustainable machining literature further studied a number of other machining processes, including drilling [92,151], electrical discharge machining [152,153], grinding [154], and laser-waterjet hybrid machining [155]. Moreover, cutting conditions improvement and optimisation studies were evident (with 17%) [156][157][158], which investigated optimal parameters, including material removal rates; depth of cut; feeds and speeds for sustainability improvements, including optimising energy consumption [153]; and reducing carbon emissions [152]. Nur et al [159] investigated various cutting conditions (i.e., cutting force), realising energy efficiency improvements for sustainable machining of an aluminium alloy (Al-11%Si).…”

Section: Thematic Map Of Sustainable Machining Technology Researchmentioning

confidence: 99%

“…Turning (43% of articles categorised under sustainable machining) and milling (with 24%) were noted as the two most popular machining processes in the SM technology research. On the other hand, sustainable machining literature further studied a number of other machining processes, including drilling [92,151], electrical discharge machining [152,153], grinding [154], and laser-waterjet hybrid machining [155].…”

Section: Sustainability Indicators Studiedmentioning

confidence: 99%

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Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

Bastas

2021

Sustainability

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Meeting current needs while not sacrificing the future ability to do so as a key sustainability concept is becoming more challenging than ever, with the increasing population rate, energy poverty, global warming, and surging demand for products and services. Manufacturing is in a prime position to address this challenge, with its significant economic contribution to the global GDP and its high influence over the environment and humanity. Sustainable manufacturing technologies research is growing to support our journey towards sustainable development. This article undertook the systematic review of state-of-the-art sustainable manufacturing technologies literature, evidencing the latest themes and trends in this important research avenue. Descriptive and thematic analyses were performed, synthesising the latest advancements in the field. Sustainable manufacturing processes, especially sustainable machining, was established as a key theme, including research endeavours of elimination of lubricants. Various manufacturing systems and process sustainability assessment technologies were noted. Sustainability indicators addressed were critically evaluated. As an outcome, a conceptual framework of sustainable manufacturing technology research was constructed to structure the knowledge acquired and to provoke future thinking. Finally, challenges and future directions were provided for both industrial and academic reader base, stimulating growth in this fruitful research stream.

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Section: Thematic Map Of Sustainable Machining Technology Researchmentioning

confidence: 99%

Section: Sustainability Indicators Studiedmentioning

confidence: 99%

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

Bastas

2021

Sustainability

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“…It revealed that current is providing an important impact on the GEC of the reacting dielectric fluid as shown in Figure 2. While increasing current, the gas emission is also increased due to an increase in the concentration of spark energy in the cutting zone (Thiyagarajan et al 2012;Dhakar et al 2019). It is caused by the increasing thermal reaction between work material and a wire tool.…”

Section: About Here>mentioning

confidence: 99%

“…It has revealed that machining performance was also improved by that method (Dong et al 2019). A study exhibited that the near-dry green EDM process decreased the 97% fume emission with maximum debris when compared to existing liquid EDM (Dhakar et al 2019). It was reviewed that the water, gas, bio-dielectric have been utilized to promote sustainable development of dry and near-dry EDM processes (Singh et al 2020).…”

Section: Introductionmentioning

confidence: 99%

Sustainable Eco-friendly Wire-cut Electrical Discharge Machining: Gas Emission Analysis

Boopathi¹

2021

Preprint

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Wire-cut electrical discharge machining (WEDM) is the highly essential unconventional electro-thermal machining process to cut the contour profile of hard materials in modern production industries. The various environmental impacting wastes (by evaporating and reacting hydro-carbon dielectric fluid) are produced during the WEDM process and these are harmful to the machine operators. These wastes are minimized by a near-dry WEDM process wherein the pressurized air mixed with a small amount of water is used as a dielectric substance. In this research, influences, and contributions of machining parameters such as air pressure, mixing water flow rate, spark current and pulse width on gas emission concentration (GEC), materials removal rate (MRR), and relative emission rate (RER) of sustainable near-dry WEDM process have been optimized by Taguchi analysis. RER is investigated to analyze the effects of machining factors on gas emission and machining rate combinedly. It was revealed that the maximum air pressure and flow rate of mixing water have significantly been promoting the sustainable near-dry WEDM process.

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“…As per ISO 14000, eco-friendly machining processes are promoted with high machining performances [5]. It was observed from the literature that harmful hazardous contaminants are emitted during the machining of various metals using EDM processes [6,7]. In EDM /WEDM processes, the evaporation of dielectric fluid reacted with eroded different work materials, and mixing of dielectric fluid with atmospheric gases are affecting the health of the machine operators [8].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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In this research, the mixing of compressed air with the minimum quantity of water is used as a dielectric medium and the cryogenically cooled molybdenum wire is used as a tool in wire-cut electrical discharge machining (WEDM) to encourage the eco-friendly production, called cryogenically cooled near-dry WEDM process. The nitrogen gas-cooled wire tool is utilized to cut the Inconel 718 alloy workpiece to prevent wire breakage and maintain enough electrical conductivity. The preliminary experiments were conducted to compare wet, dry, near-dry, and cryogenically cooled near-dry WEDM processes. It was revealed that cryogenic cooled near-dry WEDM is better performance than dry, near-dry WEDM except for the wet process. The systematic experiments of eco-friendly cryogenically cooled near-dry WEDM have been conducted to analyse the effect of input factors like spark current, pulse-width, pulse-interval, and mixing water flow rate on material removal rate (MRR) and surface roughness (SR) using Box–Behnken method. The fitted models and response surface graphs were developed to analyse the influences of input factors on each response parameter. It was concluded that MRR and SR of cryogenically cooled near-dry WEDM are increased by maximizing spark current, pulse-width, and flow rate, conversely, both responses were decreased by increasing pulse-interval. The technique for order of preference by similarity to ideal solution (TOPSIS) technique has been applied to predict the best combination of input factors for satisfying the optimal values of both responses.

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An environment-friendly and sustainable machining method: near-dry EDM

Cited by 67 publications

References 15 publications

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

Sustainable Eco-friendly Wire-cut Electrical Discharge Machining: Gas Emission Analysis

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

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