Skip to main content
SpringerLink
Log in

Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid

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

Abstract

Towards the requirement of sustainable development, manufacturing industries are required to follow ISO-14000 standards. Therefore, it is necessary to follow sustainability criteria for manufacturing processes. Vegetable oil-based fluids have proven their potential towards the various industrial applications and establish themselves as a sustainable fluids as compared to hydrocarbon and synthetic-based fluids. In the present study, the authors have evaluated the practical acceptability of newly proposed Schleichera oleosa (Kusum oil) as an alternative of hydrocarbon-based EDM oil. The improvement in machining performance of MWCNT mixed rotary EDMing of EN-31 die steel using Kusum oil as a dielectric is evaluated in terms of MRR and SR. Response surface methodology along with genetic algorithm is used for the mathematical modelling and optimization of MRR and SR both. The optimization result shows that MWCNT mixed rotary EDM using Kusum oil as a dielectric shows approximately 57.14% higher MRR and 54.57% lower SR, respectively, as compared to conventional EDM using EDM oil as a dielectric. Finally, the surface topography images obtained from FESEM analysis also confirm the superiority of Kusum oil over 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
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Abbreviations

CNT:

Carbon nanotubes

DC:

Duty cycle

FESEM:

Field emission scanning electron microscope

GA:

Genetic algorithm

I p :

Peak current

MWCNT:

Multiwall carbon nanotubes

MRR:

Material removal rate

P c :

Powder concentration

PMEDM:

Powder mixed electrical discharge machining

REDM:

Rotary electrical discharge machining

RPMEDM:

Rotary powder mixed electrical discharge machining

SR:

Surface roughness

T on :

Pulse on time

T off :

Pulse off time

TWR:

Tool wear rate

TR:

Tool rotation

References

  1. Ho K, Newman S (2003) State of the art electrical discharge machining (EDM). Int J Mach Tools Manuf 43(13):1287–1300

    Google Scholar 

  2. Panda DK, Bhoi RK (2006) Electro-discharge machining–a qualitative approach. Mater Manuf Process 21(8):853–862

    Google Scholar 

  3. Karunakaran K, Chandrasekaran M (2017) Investigation of machine-ability of Inconel 800 in EDM with coated electrode. In: IOP conference series: materials science and engineering. IOP Publishing

  4. Muthuramalingam T, Mohan B (2013) A study on improving machining characteristics of electrical discharge machining with modified transistor pulse generator. Int J Manuf Technol Manag 27(1–3):101–111

    Google Scholar 

  5. 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

    Google Scholar 

  6. 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

    Google Scholar 

  7. 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 B J Eng Manuf 223(9):1115–1126

    Google Scholar 

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

    Google Scholar 

  9. 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 

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

    Google Scholar 

  11. 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 

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

    Article  Google Scholar 

  13. 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 

  14. Yih-Fong T, Fu-Chen C (2005) Investigation into some surface characteristics of electrical discharge machined SKD-11 using powder-suspension dielectric oil. J Mater Process Technol 170(1):385–391

    Article  Google Scholar 

  15. Kansal H, Singh S, Kumar P (2005) Application of Taguchi method for optimisation of powder mixed electrical discharge machining. Int J Manuf Technol Manag 7(2–4):329–341

    Article  Google Scholar 

  16. 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 

  17. 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 

  18. 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 

  19. Izman S et al (2012) Effects of adding multiwalled carbon nanotube into dielectric when EDMing titanium alloy. Adv Mater Res 463–464:1445–1449

    Article  Google Scholar 

  20. 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

    Google Scholar 

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

    Google Scholar 

  22. 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

    Google Scholar 

  23. 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

    Google Scholar 

  24. Zhao W, Meng Q, Wang Z (2002) The application of research on powder mixed EDM in rough machining. J Mater Process Technol 129(1):30–33

    Google Scholar 

  25. Tan X et al (2002) A decision-making framework model of cutting fluid selection for green manufacturing and a case study. J Mater Process Technol 129(1–3):467–470

    Google Scholar 

  26. Gamage JR et al (2017) Sustainable machining: process energy optimisation of wire electrodischarge machining of Inconel and titanium superalloys. J Clean Prod 164:642–651

    Google Scholar 

  27. Garg A, Lam JSL (2016) Modeling multiple-response environmental and manufacturing characteristics of EDM process. J Clean Prod 137:1588–1601

    Google Scholar 

  28. Garg A, Lam JSL, Gao L (2015) Energy conservation in manufacturing operations: modelling the milling process by a new complexity-based evolutionary approach. J Clean Prod 108:34–45

    Google Scholar 

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

    Google Scholar 

  30. Gutowski T, Dahmus J, Thiriez A (2006) Electrical energy requirements for manufacturing processes. In: 13th CIRP international conference on life cycle engineering. 2006. CIRP International, Leuven, Belgium

  31. Leão FN, Pashby IR (2004) A review on the use of environmentally-friendly dielectric fluids in electrical discharge machining. J Mater Process Technol 149(1–3):341–346

    Google Scholar 

  32. Modica F et al (2011) Sustainable micro-manufacturing of micro-components via micro electrical discharge machining. Sustainability 3(12):2456–2469

    Google Scholar 

  33. Hocheng H, Chang J-H, Jadhav UU (2012) Micromachining of various metals by using Acidithiobacillus ferrooxidans 13820 culture supernatant experiments. J Clean Prod 20(1):180–185

    Google Scholar 

  34. Rotella G et al (2012) Dry and cryogenic machining: comparison from the sustainability perspective. In: Seliger G (ed) Sustainable manufacturing. Springer, Berlin, pp 95–100

    Chapter  Google Scholar 

  35. Jawahir I et al (2006) Product design and manufacturing processes for sustainability. In: Mechanical engineers' handbook, vol 3, chap 12, pp 414–443

  36. 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 Manufa Technol 87(5–8):1509–1518

    Article  Google Scholar 

  37. 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 

  38. 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 

  39. Kumar N, Pali HS (2013) Kusum oil as a potential fuel for ci engines. In: International conference on alternative fuels for IC engines (ICAFICE), Priya Tech Publication Private Ltd, Jaipur, India

  40. Pali HS, Kumar N, Mishra C (2014) Effect of blending of ethanol in kusum oil on performance and emission characteristics of a single cylinder diesel engine. SAE Technical Paper

  41. Al-Khazraji A, Amin SA, Ali SM (2016) The effect of SiC powder mixing electrical discharge machining on white layer thickness, heat flux and fatigue life of AISI D2 die steel. Eng Sci Technol Int J 19(3):1400–1415

    Google Scholar 

  42. Montgomery DC, Peck EA, Vining GG (2012) Introduction to linear regression analysis, vol 821. Wiley, Hoboken

    MATH  Google Scholar 

  43. Kansal H, Singh S, Kumar P (2007) Effect of silicon powder mixed EDM on machining rate of AISI D2 die steel. J Manuf Process 9(1):13–22

    Google Scholar 

  44. Prakash C et al (2017) Experimental investigations in powder mixed electric discharge machining of Ti–35Nb–7Ta–5Zrβ-titanium alloy. Mater Manuf Process 32(3):274–285

    Google Scholar 

  45. Prakash C et al (2016) Multi-objective optimization of powder mixed electric discharge machining parameters for fabrication of biocompatible layer on β-Ti alloy using NSGA-II coupled with Taguchi based response surface methodology. J Mech Sci Technol 30(9):4195–4204

    Google Scholar 

Download references

Acknowledgements

The authors wish to express their gratitude to Dr. H S Pali, Assistant Professor, Department of Mechanical Engineering, National Institute of Technology, Srinagar, J&K, India for their valuable help towards the testing of properties of Kusum oil. Further, authors wish their special thanks to Dr. Pranava Manjari, HOD English department, JSS Academy of Technical Education, Noida for improving the quality of the manuscript.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines), 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, Uttar Pradesh, Lucknow, 226021, India

    Arun Kumar Tiwari

Authors
  1. Rajesh Bajaj
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Amit Rai Dixit
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Arun Kumar Tiwari
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Rajesh Bajaj.

Additional information

Technical Editor: Lincoln Cardoso Brandao, Ph.D.

Publisher's Note

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

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Bajaj, R., Dixit, A.R. & Tiwari, A.K. Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid. J Braz. Soc. Mech. Sci. Eng. 42, 512 (2020). https://doi.org/10.1007/s40430-020-02597-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-020-02597-8

Keywords

Search

Navigation