Sustainable Machining of Hastelloy in EDM Using Nanoparticle-Infused Biodegradable Dielectric Fluid

Nagabhooshanam, N.; Baskar, S.; Anitha, K.; Arumugam, S.

doi:10.1007/s13369-021-05652-1

Cited by 20 publications

(7 citation statements)

References 36 publications

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“…11 (ii) fluid with high viscosity distributes the heat uniformly which eliminates the uneven machined surface. 40 (iii) A dielectric fluid with a low specific heat leads to better cooling of the electrode and work material, as well as material integrity. Of the five distinct electrodes, samples machined with B possess the least Ra value.…”

Section: Resultsmentioning

confidence: 99%

Electric Discharge Machining of Inconel 718 Under a Distinct Dielectric Medium

Somu¹,

Ranjith²

2022

ECS J. Solid State Sci. Technol.

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In this research, an attempt was made to machine the Inconel 718 alloy under varied dielectric media with the objective of generating wealth from waste and establishing a green environment. Experiments were conducted to analyze the influence of input variables under EDM oil, pure sunflower oil, used sunflower oil, palm oil, and ground nut oil insulating media. Five different tools, copper, brass, aluminium, copper–graphite, and aluminum–graphite, were utilized for investigation and experimental runs were designed using Taguchi mixed orthogonal array. The results revealed that the characteristics of the dielectric fluid influences the spark generation and machined cycle time. The findings show that dielectric fluid with a high density facilitates flushing, low specific heating distributes heat uniformly, and low carbon content eliminates black spots. An electrode with low thermal conductivity dissipates more heat and low latent heat of fusion erodes excessively. Micro pits, globules, angled and clouded blobs, black spots, material dunes and redeposited material are the various features observed on the machined surface texture.

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Section: Resultsmentioning

confidence: 99%

Electric Discharge Machining of Inconel 718 Under a Distinct Dielectric Medium

Somu¹,

Ranjith²

2022

ECS J. Solid State Sci. Technol.

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“…Behavior of Zr powder mixed canola oil at various machining condition on output measures was studied. The powder concentration (0.5 g l −1 ) produced maximum MRR compared to other concentration due to uniform distribution of discharge energy by powder particles over machining region [17]. Performance of eco-friendly oil at various input condition was presented interms of TWR and R a. it was noticed that decomposition of eco-friendly oil is higher as compared to hydrocarbon oil inturn TWR decreased [18].…”

Section: Introductionmentioning

confidence: 91%

“…Due to following reasons (1) Existence of particles in working gap decreases the heat energy supplied to work material. (2) SiC powder particles in dielectric medium can hit the tool material causes wear of machining tool [17]. From ANOVA (table 4) results, the capacitance and powder concentration have major influence on EWR compared to voltage.…”

Section: Influence Of Biodiesels On Ewr Ewr Increases Linearly With I...mentioning

confidence: 99%

Experimental investigation on micro ED milling of inconel alloy with SiC nano powder mixed Pongamia BD at different parametric condition

K V

2023

Surf. Topogr.: Metrol. Prop.

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µED-milling is an excellent micro machining process for machining of complex micro structures on conducting materials. In this paper, the feasibility of SiC nano powder mixed Pongamia BD as a dielectric medium while µED-milling of Inconel 718 alloy at different parametric settings namely capacitance (10 nf, 100 nf, 400 nf), powder concentration (0 g/L,0.1 g/L ,0.3g/L) and voltage (120v, 130v, 140v) is analysed. Further, the craters dimensions are correlated with the 3D roughness parameters (Spk, Sk and Svk) in this investigation. Lower settings of capacitance (10nF) offered a maximum MRR (601767.1µm3/s) compared to intermediate (398080.62 µm3/s) and higher (273498.29 µm3/s ) settings of capacitance. MRR is increased around 1.3 times with Pongamia BD compared to SiC nano powder mixed Pongamia BD at considered parametric settings. Crater diameter is decreased by 24.1% with SiC nano powder mixed Pongamia BD due to lesser amount heat transfer to workpiece. Droplet angle of machined surface with SiC nano powder mixed Pongamia BD is 20% higher than Pongamia BD at considered parametric settings. Capacitance and voltage have the significant influence on crater diameter and roughness. Maximum MRR (1034239.41 µm3/s) is achieved with machining condition (10nF, 120V,0g/L) for considered biodiesels. RLT appears to be higher around 27% with the processed surface of SiC nano powder mixed Pongamia BD as compared to Pongamia BD due to reaction of powder particles with work material. 3D roughness parameters (Spk, Sk and Svk) were greatly reduced due to inclusion of powder in biodiesels

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“…It is also noticed that these oil-based emissions emit metallic particles, butyl acetates, carbon emissions (CO, CO 2 ), and water-based dielectric releases nitrogen oxides (NO x ), hazardous chlorides, CO, and metallic particles. However, the environmental hazards can be alleviated by several ways like gaseous dielectric (helium or argon) and using a biodegradable oil [17]. In this work, biodegradable oil is used to cope with the hygienic issues as the illustration in Fig.…”

Section: Pm-edm Using Biodegradable Oil For Eco-friendly Machiningmentioning

confidence: 99%

“…There is strong need to make this process sustainable and eco-friendly considering the rapid scarcity of the resources. The conventional dielectric (kerosene) used in EDM poses serious health concern and also fails in terms of sustainable production specifically in EDM, thus not suitable for sustainable machining [17]. Therefore, the combined influence of PM-EDM and biodegradable dielectric can enhance the machining productivity with minimal harmful emissions.…”

Section: Introductionmentioning

confidence: 99%

Role of biodegradable dielectrics toward tool wear and dimensional accuracy in Cu-mixed die sinking EDM of Inconel 600 for sustainable machining

Ishfaq

Sana

Rehman

et al. 2023

J Braz. Soc. Mech. Sci. Eng.

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NetZero advancements for the manufacturing industry are aspiring for precision machining of difficult-to-cut materials with a high degree of accuracy, particularly for Ni-based super alloys while meeting climate protocols. The applications and properties of the foregoing materials warrant the usage of the electric discharge machining (EDM) technique. However, given the rising scarcity of resources, there is a compelling need to make this process sustainable. The standard dielectric (kerosene) employed in EDM is hazardous to one's health and fails in terms of long-term productivity. As a result, an effort has been made in this study to evaluate the potential of biodegradable dielectrics, at different copper powder concentrations for sustainable machining of Inconel 600. This investigation evaluated three powder concentrations (0.5, 1.0, and 1.5) g/100 ml for each dielectric. Output responses including electrode wear rate and overcut explicitly aid in ensuring long-term productivity. For example, EWR represents economic assessment, while overcut determines dimensional accuracy. The full factorial design method was used in the experiments, followed by a full statistical examination encompassing, parametric effects and interactions, and signal-to-noise ratio. The findings of this study revealed a decreased EWR (2.69 mm3/min), as well as a minimal overcut (0.33 mm). In case of EWR, about 39% variation in the magnitude has been noted when dielectrics have been varied, whereas approximately 30.9% variation in EWR was observed against the change in the powder concentration. For overcut, the influence of the dielectric on the response magnitude has been further improved as it produces about 61% variation in the OC value. However, the impact of the change in powder concentration for overcut is 8%. It was found that Amla oil with a powder concentration of 0.5 g/100 ml produced the least tool wear, but Sunflower oil at minimum powder concentration (0.5 g/100 ml) produced the minimum overcut. As a result, the combined effect of all of the aforesaid strategies results in more sustainable and dimensionally accurate machining.

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Sustainable Machining of Hastelloy in EDM Using Nanoparticle-Infused Biodegradable Dielectric Fluid

Cited by 20 publications

References 36 publications

Electric Discharge Machining of Inconel 718 Under a Distinct Dielectric Medium

Electric Discharge Machining of Inconel 718 Under a Distinct Dielectric Medium

Experimental investigation on micro ED milling of inconel alloy with SiC nano powder mixed Pongamia BD at different parametric condition

Role of biodegradable dielectrics toward tool wear and dimensional accuracy in Cu-mixed die sinking EDM of Inconel 600 for sustainable machining

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