Skip to main content
SpringerLink
Log in

Machining performance and sustainability analysis of PMEDM process using green dielectric fluid

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

Abstract

In the present work, an effort is made to evaluate the machining performance of the nano-powder mixed rotary electrical discharge machining (EDM) process by replacing the conventional EDM oil with environmentally friendly biodegradable Jatropha curcas oil (JCO). The performance of nano-powder mixed rotary EDM using JCO dielectric is compared with the conventional EDM process. Peak current, pulse on time, pulse off time, nano-powder concentration, and tool rpm are essential parameters to examine the material removal rate (MRR) and surface roughness (SR) of the EN-31 die steel. It is revealed from the results that the proposed modified EDM process shows a 73% improvement in MRR and 50% reduction in SR as compared to the conventional EDM process using EDM oil. Further, surface morphology, recast layer thickness (RLT) analysis, and microhardness analysis reveals that multi-wall carbon nanotube mixed rotary EDM using JCO shows small micro holes, no micro crack, smaller size debris deposition, lower RLT, and smaller microhardness of recast layer as compared to EDM oil. Finally, the sustainability indexes (SI) analysis result reveals that JCO is environmentally safe and economically justified due to a 9.92% lower SI value as compared to EDM oil.

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
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Data availability

The datasets used or analysed during the Machining process are available from the corresponding author upon reasonable request.

Abbreviations

ANOVA:

Analysis of variance

GA:

Genetic algorithm

I p :

Peak current

T on :

Pulse on time

T off :

Pulse off time

P c :

Powder concentration

RSM:

Response surface methodology

TR:

Tool rotation

MRR:

Material removal rate

TWR:

Tool wear rate

SR:

Surface roughness

MWCNT:

Multi-wall carbon nanotube

MOO:

Multi-objective optimization

FESEM:

Field emission scanning electron microscope

RLT:

Recast layer thickness

NPMEDM:

Nano powder mixed EDM

SI:

Sustainability index

JCO:

Jatropha curcas oil

TOPSIS:

Technique for order preference by similarity to ideal solution

GRA:

Grey relational analysis

References

  1. Boothroyd G (1989) Non-conventional machining processes. In: Fundamentals of machining and machine tools. Marcel Dekker Inc, New York

  2. Nanu D, Nanu A (2008) Perspectives of the dimensional processing through electric erosion processing. Nonconv Technol 3:61–64

    Google Scholar 

  3. Qin Y (2010) Micromanufacturing engineering and technology. William Andrew

    Google Scholar 

  4. Kiyak M, Çakır O (2007) Examination of machining parameters on surface roughness in EDM of tool steel. J Mater Process Technol 191(1–3):141–144

    Article  Google Scholar 

  5. Karunakaran K, Chandrasekaran M (2017) Investigation of machine-ability of Inconel 800 in EDM with coated electrode. IOP Conf Ser Mater Sci Eng 183:012014

    Article  Google Scholar 

  6. Muthuramalingam T, Mohan B, Jothilingam A (2014) Effect of tool electrode resolidification on surface hardness in electrical discharge machining. Mater Manuf Process 29(11–12):1374–1380

    Article  Google Scholar 

  7. Zhang Q et al (2005) A theoretical model of surface roughness in ultrasonic vibration assisted electrical discharge machining in gas. Int J Manuf Technol Manag 7(2–4):381–390

    Article  Google Scholar 

  8. Jafferson J, Hariharan P, Ram Kumar J (2014) Effects of ultrasonic vibration and magnetic field in micro-EDM milling of nonmagnetic material. Mater Manuf Process 29(3):357–363

    Article  Google Scholar 

  9. Shabgard M, Farahmand M, Ivanov A (2009) Mathematical modelling and comparative study of the machining characteristics in ultrasonic-assisted electrical discharge machining of cemented tungsten carbide (WC-10% Co). Proc Inst Mech Eng Part B J Eng Manuf 223(9):1115–1126

    Article  Google Scholar 

  10. Guu Y, Hocheng HJ (2001) Effects of workpiece rotation on machinability during electrical-discharge machining. Mater Manuf Process 16(1):91–101

    Article  Google Scholar 

  11. Baseri H, Aliakbari E, Alinejad G (2012) Investigation of the rotary EDM process of X210Cr12. Int J Mach Mach Mater 11(3):297–307

    Google Scholar 

  12. Dhakar K, Dvivedi A (2016) Parametric evaluation on near-dry electric discharge machining. Mater Manuf Process 31(4):413–421

    Article  Google Scholar 

  13. Singh NK, Pandey PM, Singh KK (2017) Experimental investigations into the performance of EDM using argon gas-assisted perforated electrodes. Mater Manuf Process 32(9):940–951

    Article  Google Scholar 

  14. Baseri H, Sadeghian S (2016) Effects of nanopowder TiO2-mixed dielectric and rotary tool on EDM. Int J Adv Manuf Technol 83(1–4):519–528

    Article  Google Scholar 

  15. Patel S, Thesiya D, Rajurkar A (2018) Aluminium powder mixed rotary electric discharge machining (PMEDM) on Inconel 718. Aust J Mech Eng 16(1):21–30

    Article  Google Scholar 

  16. Kozak J, Rozenek M, Dabrowski L (2003) Study of electrical discharge machining using powder-suspended working media. Proc Inst Mech Eng Part B J Eng Manuf 217(11):1597–1602

    Article  Google Scholar 

  17. Jeswani M (1981) Effect of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge machining. Wear 70(2):133–139

    Article  Google Scholar 

  18. Assarzadeh S, Ghoreishi M (2013) A dual response surface-desirability approach to process modeling and optimization of Al2O3 powder-mixed electrical discharge machining (PMEDM) parameters. Int J Adv Manuf Technol 64(9–12):1459–1477

    Article  Google Scholar 

  19. Bhattacharya A, Batish A, Kumar N (2013) Surface characterization and material migration during surface modification of die steels with silicon, graphite and tungsten powder in EDM process. J Mech Sci Technol 27(1):133

    Article  Google Scholar 

  20. Bhattacharya A, Batish A, Singh G (2012) Optimization of powder mixed electric discharge machining using dummy treated experimental design with analytic hierarchy process. Proc Inst Mech Eng Part B J Eng Manuf 226(1):103–116

    Article  Google Scholar 

  21. Peças P, Henriques E (2008) Effect of the powder concentration and dielectric flow in the surface morphology in electrical discharge machining with powder-mixed dielectric (PMD-EDM). Int J Adv Manuf Technol 37(11–12):1120–1132

    Article  Google Scholar 

  22. Prihandana GS et al (2011) Accuracy improvement in nanographite powder-suspended dielectric fluid for micro-electrical discharge machining processes. Int J Adv Manuf Technol 56(1–4):143–149

    Article  Google Scholar 

  23. Jahan MP, Rahman M, San Wong Y (2011) Study on the nano-powder-mixed sinking and milling micro-EDM of WC-Co. Int J Adv Manuf Technol 53(1–4):167–180

    Article  Google Scholar 

  24. Prabhu S, Vinayagam B (2011) AFM surface investigation of Inconel 825 with multi wall carbon nano tube in electrical discharge machining process using Taguchi analysis. Arch Civ Mech Eng 11(1):149–170

    Article  Google Scholar 

  25. Mai C, Hocheng H, Huang S (2012) Advantages of carbon nanotubes in electrical discharge machining. Int J Adv Manuf Technol 59(1–4):111–117

    Article  Google Scholar 

  26. Izman S et al (2012) Effects of adding multiwalled carbon nanotube into dielectric when EDMing titanium alloy. Adv Mater Res. https://doi.org/10.4028/www.scientific.net/AMR.463-464.1445

    Article  Google Scholar 

  27. Sari MM, Noordin M, Brusa E (2013) Role of multi-wall carbon nanotubes on the main parameters of the electrical discharge machining (EDM) process. Int J Adv Manuf Technol 68(5–8):1095–1102

    Article  Google Scholar 

  28. Prabhu S, Vinayagam B (2016) Optimization of carbon nanotube based electrical discharge machining parameters using full factorial design and genetic algorithm. Aust J Mech Eng 14(3):161–173

    Article  Google Scholar 

  29. Mohal S, Kumar H (2017) Parametric optimization of multiwalled carbon nanotube-assisted electric discharge machining of Al-10% SiCp metal matrix composite by response surface methodology. Mater Manuf Process 32(3):263–273

    Article  Google Scholar 

  30. Dwivedi AP, Choudhury SK (2016) Effect of tool rotation on MRR, TWR, and surface integrity of AISI-D3 steel using the rotary EDM process. Mater Manuf Process 31(14):1844–1852

    Article  Google Scholar 

  31. Marashi H et al (2016) State of the art in powder mixed dielectric for EDM applications. Precis Eng 46:11–33

    Article  Google Scholar 

  32. Valaki JB, Rathod PP (2016) Assessment of operational feasibility of waste vegetable oil based bio-dielectric fluid for sustainable electric discharge machining (EDM). Int J Adv Manuf Technol 87(5–8):1509–1518

    Article  Google Scholar 

  33. Valaki JB, Rathod PP (2016) Investigating feasibility through performance analysis of green dielectrics for sustainable electric discharge machining. Mater Manuf Process 31(4):541–549

    Article  Google Scholar 

  34. Valaki JB, Rathod PP, Sankhavara C (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

    Article  Google Scholar 

  35. Long BT et al (2016) Optimization of PMEDM process parameter for maximizing material removal rate by Taguchi’s method. Int J Adv Manuf Technol 87(5):1929–1939

    Article  Google Scholar 

  36. Nguyen H-P, Pham V-D, Ngo N-V (2018) Application of TOPSIS to Taguchi method for multi-characteristic optimization of electrical discharge machining with titanium powder mixed into dielectric fluid. Int J Adv Manuf Technol 98(5):1179–1198

    Article  Google Scholar 

  37. Nguyen TD, Nguyen PH, Banh LT (2019) Die steel surface layer quality improvement in titanium μ-powder mixed die sinking electrical discharge machining. Int J Adv Manuf Technol 100(9):2637–2651

    Article  Google Scholar 

  38. Banh T-L et al (2018) Characteristics optimization of powder mixed electric discharge machining using titanium powder for die steel materials. Proc Inst Mech Eng Part E J Process Mech Eng 232(3):281–298

    Article  Google Scholar 

  39. HuuPhan N et al (2020) Influence of micro size titanium powder-mixed dielectric medium on surface quality measures in EDM process. Int J Adv Manuf Technol 109(3):797–807

    Article  Google Scholar 

  40. Huu P-N (2020) Multi-objective optimization in titanium powder mixed electrical discharge machining process parameters for die steels. Alex Eng J 59(6):4063–4079

    Article  Google Scholar 

  41. Taherkhani A et al (2021) Investigation of surface quality in cost of goods manufactured (COGM) method of μ-Al2O3 powder-mixed-EDM process on machining of Ti-6Al-4V. Int J Adv Manuf Technol 116(5):1783–1799

    Article  Google Scholar 

  42. Bajaj R, Dixit AR, Tiwari AK (2020) Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid. J Braz Soc Mech Sci Eng 42(10):1–20

    Article  Google Scholar 

  43. Furutania K et al (2001) Accretion of titanium carbide by electrical discharge machining with powder suspended in working fluid. Precis Eng 25(2):138–144

    Article  Google Scholar 

  44. Montgomery DC, Peck EA, Vining GG (2012) Introduction to linear regression analysis. Wiley, Hoboken

    MATH  Google Scholar 

  45. Kansal H, Singh S, Kumar P (2005) Parametric optimization of powder mixed electrical discharge machining by response surface methodology. J Mater Process Technol 169(3):427–436

    Article  Google Scholar 

  46. Gill AS, Kumar S (2019) Surface characteristics investigation of tool steel machined by powder metallurgy tool in EDA. Mater Res Exp 6(12):1265b1

    Article  Google Scholar 

  47. Pellegrini G, Ravasio C (2019) Evaluation of the sustainability of the micro-electrical discharge milling process. J Adv Prod Eng Manag 14(3):343–354

    Google Scholar 

  48. Moldavska A, Welo T (2017) The concept of sustainable manufacturing and its definitions: a content-analysis based literature review. J Clean Prod 166:744–755

    Article  Google Scholar 

  49. Wang X et al (2018) Evaluation of EDM process for green manufacturing. Int J Adv Manuf Technol 94(1–4):633–641

    Article  Google Scholar 

Download references

Funding

This article does not involve any funding from any agency.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology (ISM), Dhanbad, 826004, India

    Rajesh Bajaj & Amit Rai Dixit

  2. Department of Mechanical Engineering, JSS Academy of Technical Education, Noida, 201301, India

    Rajesh Bajaj

  3. Department of Mechanical Engineering, Institute of Engineering and Technology, Dr. A.P.J. Abdul Kalam Technical University, Lucknow, Uttar Pradesh, 226021, India

    Arun Kumar Tiwari

  4. Mechanical Engineering Department, Curtin University, Bentley, WA, 6155, Australia

    Alokesh Pramanik

  5. Department of Mechanical Engineering, G L Bajaj Institute of Technology and Management, Greater Noida, 201308, India

    Ashish Kumar Srivastava

Authors
  1. Rajesh Bajaj
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Arun Kumar Tiwari
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Alokesh Pramanik
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Ashish Kumar Srivastava
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Amit Rai Dixit
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All the authors have significantly contributed to prepare the article. Following is the contribution of individual Author: RB: Gap identification and conceptualization of the process along with all the experimental work. AKT: critical review and consolidation of write-up in proper format. AP: Data analysis of the manuscript. ARD: Conduction of experimentation. AKS: Formal analysis and data compilation.

Corresponding author

Correspondence to Amit Rai Dixit.

Ethics declarations

Conflict of interest

The authors declare no conflict of interest.

Ethical approval

This chapter does not contain any studies with human participants or animals performed by any of the authors. Authors acknowledge the work is original and all the relevant text from the literature has been properly cited.

Consent to participate

Authors agree to the authorship order.

Consent to publish

All authors have read and agreed to the published version of the manuscript.

Additional information

Technical Editor: Lincoln Cardoso Brandao.

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

Bajaj, R., Tiwari, A.K., Pramanik, A. et al. Machining performance and sustainability analysis of PMEDM process using green dielectric fluid. J Braz. Soc. Mech. Sci. Eng. 44, 563 (2022). https://doi.org/10.1007/s40430-022-03878-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-022-03878-0

Keywords

Search

Navigation