Investigating Feasibility Through Performance Analysis of Green Dielectrics for Sustainable Electric Discharge Machining

Abstract

This work represents a feasibility study for the newly proposed vegetable oil based green dielectric fluids, biodielectric1 (BD1) and biodielectric2 (BD2) for Electric discharge machining (EDM). Comparative analyses for BD1, BD2 and kerosene have been studied to assess the performance in terms of material removal Rate (MRR), electrode wear rate (EWR) and relative wear ratio (RWR) for P20+ cold worked plastic injection mould steel using electrolytic grade copper electrode. Current, Gap voltage, Pulse on time (T on ) andPulse off time (T off ), have been chosen as input parameters and one variable at a time approach has been used for designing experimental plan for investigating feasibility of the newly suggested fluids. The results obtained show that performance of the newly suggested biodielectrics BD1 and BD2 are better than commercially used hydrocarbon based dielectric i.e. Kerosene, for MRR and RWR. ANOVA results indicated that current is the most influencing parameter for MRR and EWR, while T on is the most significant parameter for RWR. Under the influence of current, BD1 and BD2 produced 38% and Downloaded by [New York University] at 00:10 02 August 2015 2165 % improvement in MRR respectively. Moreover, BD1 and BD2 resulted 30% higher and 7% lower RWR, respectively under the influence of T on.

Feasibility assessment of some alternative dielectric mediums for sustainable electrical discharge machining: a review work

“…The maximum MRR has been reported as 53.33 mm 3 /min for jatropha and 29.21 mm 3 /min for kerosene, when 18 A current, 200 µs pulse-on time, 20 µs pulse-off time, and 50 V gap voltage were maintained. Similar types of results are also noticed when WVO, palm oil, canola, and sunflower were used as dielectrics [15,61,62]. Lately, Das et al [18] investigated the performance of neem oil as a dielectric to machine Ti-6Al-4V with copper electrode, where 4-16 A current, 20-60 V gap voltage, 50-250 µs of pulse-on time, and 10-50 µs of pulse-off time were maintained.…”

“…It was observed that the dry EDM process gave better and impressive surface quality as well as small size crack on machined surface when compared to wet EDM. It was also found that the concentration of crack was more on the wall, which significantly varied with machining condition (i.e., with current, voltage, and pulse duration) Water and air [61] Steel PCD Polycrystalline diamond (PDC) possesses poor machining efficiency during EDM operation, but while machined with water as a dielectric, impressive MRR was observed. Moreover, the sharpening process of PCD with steel as an electrode gave suitable value of MRR and surface integrity along with less electrode consumption, which was better than kerosene or EDM oil [38] Water-aqueous solution of calcium chloride…”

“…In this aspect, properties like oxygen content, flash point, viscosity, and density play a notable impact on the responses and should be considered during the dielectric selection. Lately, palm oil is used as a dielectric, which ensures better sustainability with 38% more MRR [61]. Similar approach, where bio-dielectrics ensured 38-138% more MRR and better surface properties, but caused 100-275% more TW than kerosene [62].…”

Energy Consumption Modeling for EDM Based on Material Removal Rate

“…The energy efficiency Ee and removal efficiency Re of micro EDM were theoretically analyzed by Mohd et al [21]. Similarly, many researchers have attempted the use of new green materials and media [22][23][24] in electrical processing, which has improved the quality of the processing environment, effectively reduced energy consumption and improved the processing efficiency in actual production. Other scholars have reduced energy consumption by controlling the pulse power or improving the processing technology [25][26][27][28], which is easy to achieve in actual processing and reduces power consumption to some extent.…”

Experimental Characterization of Electrical Discharge Machining of Aluminum 6061 T6 Alloy using Different Dielectrics

“…They reported that liquid dielectrics exhibited better material removal efficiency, while water-oil emulsion sustained pressure for a longer time. Valaki and Rathod [16] analyzed bio-dielectrics developed from vegetable oil and kerosene while machining P20 steel, the bio-dielectrics showed better results than kerosene for MRR and EWR. Furthermore, EDM process using water oil emulsion showed that both MRR and surface roughness (SR) were influenced greatly by current.…”