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A review on sustainability, health, and safety issues of electrical discharge machining

  • Review
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Electrical discharge machining (EDM) is a well-practiced non-traditional machining process in the manufacturing, aerospace, and biomedical instrumentation industry, used to machine hard metals, alloys, composites, and ceramics. But EDM has some demerits such as low material removal rate (MRR), high power consumption, and dependency on conventional fluids (kerosene and hydrocarbon oil as dielectric), which lowers its sustainability index. Besides these, toxic fumes, vapors, and aerosols are released during the process. Generation of toxic and non-biodegradable dielectric waste and its disposal is also a severe problem. The toxic gases adversely affect the environment and human beings. The risk of fire and health hazards to the operator is also a cause of concern. The present article deeply emphasizes the issue of the emergence of toxic fumes during machining and the use of some alternative dielectric mediums, which are the justified and potential substitutes of conventional EDM oils. This review article mainly focuses on the machining performance of different green EDM techniques, the environmental impact of EDM, and personnel health and operational safety. Various types of diseases caused by toxic gases are also reviewed. This review article is based on  299 articles published from 1981 to 2021. A detailed discussion on water-based dielectrics, powder-mixed EDM, vegetable oil-based EDM, dry and near-dry EDM is presented in the paper. Finally, the article winds up with research gaps and future scope and concluding remarks.

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Reproduced with permission from Suthangathan et al. [90])

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Reproduced with permission from Kao et al. [105])

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Reproduced with permission from Li et al. [111])

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Reproduced with permission from Liqing and Yingjie [208])

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Abbreviations

ANOVA:

Analysis of variance

BUVO:

Blended used vegetable oil

CWD:

Commercial water-based dielectrics

DEDM:

Dry electrical discharge machining

DEMATEL:

Decision-making trial and evaluation laboratory

ECM:

Electro chemical machining

EDM:

Electrical discharge machining

EDX:

Energy-dispersive X-ray analysis

EWR:

Electrode wear ratio

GRA:

Grey relational analysis

HAZ:

Heat-affected zone

MFADEDM:

Magnetic field-assisted dry electrical discharge machining

µEDM:

Micro-electrical discharge machining

MQL:

Minimum quantity lubrication

MRR:

Material removal rate

NDEDM:

Near-dry electrical discharge machining

OCW:

Organic compound mixed water

PAH:

Polycyclic aromatic hydrocarbons

PAS:

Portable spectrometer aerosol

PMEDM:

Powder-mixed electrical discharge machining

REWR:

Relative electrode wear ratio

SF:

Surface finish

SR:

Surface roughness

USDEDM:

Ultrasonic-assisted dry electrical discharge machining

WEDM:

Wire electrical discharge machine

WMFADEDM:

Without magnetic field-assisted dry electrical discharge machining

WPMEDM:

Water-based powder-mixed EDM

WVO:

Waste vegetable oil

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  1. Department of Mechanical Engineering, National Institute of Technology Silchar, Assam, 788010, India

    Binoy Kumar Baroi & Promod Kumar Patowari

  2. Department of Mechanical Engineering, National Institute of Technology Raipur, Chhattisgarh, 492010, India

    Jagadish

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Baroi, B.K., Jagadish & Patowari, P.K. A review on sustainability, health, and safety issues of electrical discharge machining. J Braz. Soc. Mech. Sci. Eng. 44, 59 (2022). https://doi.org/10.1007/s40430-021-03351-4

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