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Analysis of a novel sustainability framework based on economic and environmental aspects in graphene-based dielectric electric discharge machining

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Abstract

Only a few studies are conducted to change a non-conventional die-sinking electric discharge to sustainable machining of hard materials with intricate geometries, for which economic or environmental aspects need to be considered. Sustainable machining of such a hard material is a challenge nowadays. This research aims to achieve sustainable manufacturing of an electric discharge machining of AISI D2 steel using nanofluids. Graphene nanoplatelets mixed with kerosene oil were used as nanofluids. Sustainability is achieved through economic and environmental factors, which mainly include productivity (material removal rate), surface quality (surface roughness and white layer), and cost (overhead, electricity, nanofluids, and wasted coolant), as well as the environment (discharge energy and material consumptions). A sustainability framework is developed to prioritize the significant factors related to green manufacturing and compare the alternatives. A total of nine factors are grouped into four categories: productivity, surface defects, cost analysis, and environmental impacts are selected for the study. The effect of the four most influencing factors, pulse-off time, discharge current, pulse-on time, and concentration of nanoparticles with respect to sustainable performance measures, are investigated. The results depict that surface defects, such as surface roughness and white layer, are significant factors, followed by productivity and cost (overhead, electricity, nanofluids, and wasted coolant). The results show that the environmental aspect of sustainable manufacturing is less important than the others at the early stages as per experimental data and expert opinions. For international certifications, both economic and environmental aspects should be addressed as per international standards.

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Acknowledgements

The authors would like to acknowledge the support provided by the Wuhan National Laboratory of Optoelectronics (WNLO) and Huazhong University of Science and Technology, Wuhan, China, by providing the material testing facility. The authors would also like to acknowledge Ms. Bettina Mauser, Germany, for English proofreading.

Funding

This work was financially supported by the National Key R&D Programs of China (Number: 2019YFB1311100) and the Open Topics of State Key Lab of Digital Manufacturing Equipment & Technology of Huazhong University of Science and Technology (Number: DMETKF2020003).

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Authors and Affiliations

  1. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China

    Muhammad Hanif & Li Zhang

  2. Department of Industrial Engineering, University of Engineering and Technology, Taxila, Pakistan

    Wasim Ahmad

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  1. Muhammad Hanif
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  2. Li Zhang
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  3. Wasim Ahmad
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Correspondence to Muhammad Hanif.

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Hanif, M., Zhang, L. & Ahmad, W. Analysis of a novel sustainability framework based on economic and environmental aspects in graphene-based dielectric electric discharge machining. Int J Adv Manuf Technol 119, 6287–6306 (2022). https://doi.org/10.1007/s00170-021-08548-4

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