Skip to main content
SpringerLink
Log in

Experimental investigation of effective parameters on productivity improvement of the EDM process for corrosion-resistant metals

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Inconel 625 superalloy and stainless steel 304 are known for their significant corrosion resistance along with their high hardness and strength. Therefore, they are used in a wide range of industries, including oil and gas and nuclear. Electrical discharge machining is among the most widely used processes for machining of these metals. However, this process has limitations, such as low material removal efficiency, high surface roughness, and the formation of a recast layer. Therefore, in this study, the effective parameters on increasing the material removal efficiency and reducing recast layer thickness are investigated. These parameters include the dielectric fluid, electrode material, discharge current, and pulse duration. After performing the test matrix, the effect of each of the input parameters on the material removal rate, surface roughness, and thickness of the recast layer is evaluated using the ANOVA method. The results of this analysis showed that the type of dielectric fluid and the presence of silver oxide nanoparticles have a significant effect on output variables. When using sunflower oil fluid containing nanoparticles and the silver electrode, the recast layer and surface roughness are reduced, while the average material removal rate increases by 40% compared to the traditional mode. Also, due to the biodegradability of deionized water and sunflower oil fluids, the environmental sustainability of the process in this study is increased and while increasing productivity, it leads to the sustainable development of the EDM process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

References

  1. Das S, Paul S, Doloi B (2019) An experimental and computational study on the feasibility of bio-dielectrics for sustainable electrical discharge machining. J Manuf Process 41:284–296. https://doi.org/10.1016/j.jmapro.2019.04.005

    Article  Google Scholar 

  2. Kalyanakumar S, Prabhu L, Saravanan M, Imthiyas A (2020) Experimental investigation of MRR, RA of 304 stainless steel using WEDM. IOP Conference Series: Materials Science and Engineering 993(1):012035. https://doi.org/10.1088/1757-899x/993/1/012035

    Article  Google Scholar 

  3. Ming W, Jia H, Zhang H, Zhang Z, Liu K, Du J, Shen F, Zhang G (2020) A comprehensive review of electric discharge machining of advanced ceramics. Ceram Int 46(14):21813–21838. https://doi.org/10.1016/j.ceramint.2020.05.207

    Article  Google Scholar 

  4. Abidi MH, Al-Ahmari AM, Umer U, Rasheed MS (2018) Multi-objective optimization of micro-electrical discharge machining of nickel-titanium-based shape memory alloy using MOGA-II. Measurement 125:336–349. https://doi.org/10.1016/j.measurement.2018.04.096

    Article  Google Scholar 

  5. Paswan K, Pramanik A, Chattopadhyaya S, Basak AK (2020) A novel approach towards sustainable electrical discharge machining of metal matrix composites (MMCs). Int J Adv Manuf Technol 106(3):1477–1486. https://doi.org/10.1007/s00170-019-04816-6

    Article  Google Scholar 

  6. Azam M, Jahanzaib M, Abbasi JA, Abbas M, Wasim A, Hussain S (2016) Parametric analysis of recast layer formation in wire-cut EDM of HSLA steel. Int J Adv Manuf Technol 87(1):713–722. https://doi.org/10.1007/s00170-016-8518-3

    Article  Google Scholar 

  7. Le V (2022) An investigation on machined performance and recast layer properties of AISI H13 steel by powder mixed-EDM in fine-finishing process. Mater Chem Phys 276

  8. Li C, Xu X, Li Y, Tong H, Ding S, Kong Q, Zhao L, Ding J (2019) Effects of dielectric fluids on surface integrity for the recast layer in high speed EDM drilling of nickel alloy. J Alloy Compd 783:95–102. https://doi.org/10.1016/j.jallcom.2018.12.283

    Article  Google Scholar 

  9. Dong H, Liu Y, Li M, Zhou Y, Liu T, Li D, Sun Q, Zhang Y, Ji R (2019) Sustainable electrical discharge machining using water in oil nanoemulsion. J Manuf Process 46:118–128. https://doi.org/10.1016/j.jmapro.2019.08.035

    Article  Google Scholar 

  10. Valaki JB, Rathod PP, Sankhavara CD (2016) Investigations on technical feasibility of Jatropha curcas oil based bio dielectric fluid for sustainable electric discharge machining (EDM). J Manuf Process 22:151–160. https://doi.org/10.1016/j.jmapro.2016.03.004

    Article  Google Scholar 

  11. Nas E, Akıncıoğlu S (2019) Optimization of cryogenic treated nickel-based superalloy in terms of electro erosion processing performance. Acad Platform J Eng Sci 7(1):115–126

    Google Scholar 

  12. Akıncıoğlu S (2022) Taguchi optimization of multiple performance characteristics in the electrical discharge machining of the TiGr2. Facta Univ Series: Mech Eng 20(2):237–253

    Google Scholar 

  13. Shabgard MR, Khosrozadeh B (2016) Comparative study of adding nanopowders in dielectric effects on outputs and surface integrity of Ti-6Al-4V alloy in electrical discharge machining. Modares Mech Eng 16(2):41–50

    Google Scholar 

  14. Sivaprakasam P, Hariharan P, Gowri S (2019) Experimental investigations on nano powder mixed micro-wire EDM process of inconel-718 alloy. Measurement 147:106844. https://doi.org/10.1016/j.measurement.2019.07.072

    Article  Google Scholar 

  15. Paul BK, Sahu SK, Jadam T, Datta S, Dhupal D, Mahapatra SS (2018) Effects of addition of copper powder in the dielectric media (EDM oil) on electro-discharge machining performance of Inconel 718 super alloys. Mater Today: Proc 5 (9, Part 3):17618–17626. https://doi.org/10.1016/j.matpr.2018.06.080

  16. Kumar A, Mandal A, Dixit AR, Das AK, Kumar S, Ranjan R (2019) Comparison in the performance of EDM and NPMEDM using Al2O3 nanopowder as an impurity in DI water dielectric. Int J Adv Manuf Technol 100(5):1327–1339. https://doi.org/10.1007/s00170-018-3126-z

    Article  Google Scholar 

  17. Hourmand M, Sarhan AAD, Farahany S, Sayuti M (2019) Microstructure characterization and maximization of the material removal rate in nano-powder mixed EDM of Al-Mg2Si metal matrix composite—ANFIS and RSM approaches. Int J Adv Manuf Technol 101(9):2723–2737. https://doi.org/10.1007/s00170-018-3130-3

    Article  Google Scholar 

  18. Ng PS, Kong SA, Yeo SH (2017) Investigation of biodiesel dielectric in sustainable electrical discharge machining. Int J Adv Manuf Technol 90(9):2549–2556. https://doi.org/10.1007/s00170-016-9572-6

    Article  Google Scholar 

  19. Das AK, Kumar P, Sethi A, Singh PK, Hussain M (2016) Influence of process parameters on the surface integrity of micro-holes of SS304 obtained by micro-EDM. J Braz Soc Mech Sci Eng 38(7):2029–2037. https://doi.org/10.1007/s40430-016-0488-8

    Article  Google Scholar 

  20. Phate M, Toney S, Phate V (2020) Modelling and investigating the impact of EDM parameters on surface roughness in EDM of Al/Cu/Ni Alloy. Aust J Mech Eng:1–14. https://doi.org/10.1080/14484846.2020.1790478

  21. Luzia CAO, Laurindo CAH, Soares PC, Torres RD, Mendes LA, Amorim FL (2019) Recast layer mechanical properties of tool steel after electrical discharge machining with silicon powder in the dielectric. Int J Adv Manuf Technol 103(1):15–28. https://doi.org/10.1007/s00170-019-03549-w

    Article  Google Scholar 

  22. Muttamara A, Kanchanomai C (2016) Effect of carbon in the dielectric fluid and workpieces on the characteristics of recast layers machined by electrical discharge machining. Metall and Mater Trans A 47(6):3248–3255. https://doi.org/10.1007/s11661-016-3452-4

    Article  Google Scholar 

Download references

Funding

The research of the corresponding author is supported by a grant from Ferdowsi University of Mashhad (N.3/51627).

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering, Ferdowsi University of Mashhad, Azadi Square, P.O. Box: 9177948944, Mashhad, Iran

    Mohammad Reza Saberi & Amirmohammad Ghandehariun

Authors
  1. Mohammad Reza Saberi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Amirmohammad Ghandehariun
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All the authors contributed to the study conception, design, material preparation, data collection, and analysis. The first draft of the manuscript was written by Mohammad Reza Saberi, and all the authors commented on previous versions of the manuscript. All the authors read and approved the final manuscript.

Corresponding author

Correspondence to Amirmohammad Ghandehariun.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Saberi, M.R., Ghandehariun, A. Experimental investigation of effective parameters on productivity improvement of the EDM process for corrosion-resistant metals. Int J Adv Manuf Technol 124, 1763–1774 (2023). https://doi.org/10.1007/s00170-022-10559-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10559-8

Keywords

Search

Navigation