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A comparative study on the effect of deep and shallow cryogenic electrodes on tool wear rate and overcut with waste bio-oil in electric discharge machining

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Abstract

The challenging characteristics of Inconel 617 (IN617), such as its modest modulus of elasticity, heightened chemical reactivity, and low thermal conductivity, pose difficulties in employing conventional machining methods for this material. This complexity is further amplified when considering the specific requirements for applications in aerospace. Consequently, electric discharge machining (EDM) emerges as a preferred approach for working with this alloy. However, inherent challenges within EDM, specifically electrode wear rate (EWR) and dimensional overcuts, limit its efficacy. To address these issues, a comprehensive exploration of the potential of powder-based additives in waste cooking oil (WCO) against cryogenically treated brass electrode material has been undertaken. The investigation holds pivotal importance because the careful choice of an optimal dielectric plays a significant role in affecting the heat input to the electrode, thereby influencing the melting/vaporization and tool wear of the electrode. It is essential to highlight that these considerations have not been adequately addressed in the current body of literature. The experimentation employs the Response Surface Methodology (RSM) experimental design. The findings indicate that the shallow cryogenically treated (SCT) brass electrode exhibited exceptional performance, yielding the lowest values for electrode wear rate (EWR) at 1.49 mg/min and dimensional overcuts (OC) at 0.01 mm. These results are notably superior, surpassing the least values obtained with the deep cryogenically treated (DCT) brass electrode, showcasing a 202.68% improvement in EWR and a 2.33% improvement in OC.

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Acknowledgements

The authors appreciate the support from Researchers Supporting Project Number (RSPD2024R702), King Saud University, Riyadh, Saudi Arabia.

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Muhammad Sana, Kashif Ishfaq & Muhammad Umair Waseem

  2. Industrial Engineering Department, College of Engineering, King Saud University, P.O. Box 800, Riyadh, 11421, Saudi Arabia

    Saqib Anwar

  3. Intelligent Systems Center, Missouri University of Science and Technology, Rolla, MO, 65409, USA

    Muhammad Arif Mahmood

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Sana, M., Ishfaq, K., Waseem, M.U. et al. A comparative study on the effect of deep and shallow cryogenic electrodes on tool wear rate and overcut with waste bio-oil in electric discharge machining. Int J Adv Manuf Technol 130, 3307–3322 (2024). https://doi.org/10.1007/s00170-023-12860-6

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