Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid
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(2020) 42:512
TECHNICAL PAPER
Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid Rajesh Bajaj1,2 · Amit Rai Dixit1 · Arun Kumar Tiwari3 Received: 20 February 2019 / Accepted: 4 September 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020
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. Keywords Sustainability · Bio-dielectric fluid · Material removal rate · Surface roughness · Response surface methodology · Genetic algorithm Abbreviations CNT Carbon nanotubes DC Duty cycle FESEM Field emission scanning electron microscope GA Genetic algorithm Ip Peak current MWCNT Multiwall carbon nanotubes MRR Material removal rate Pc Powder concentration PMEDM Powder mixed electrical discharge machining REDM Rotary electrical discharge machining Technical Editor: Lincoln Cardoso Brandao, Ph.D. * Rajesh Bajaj [email protected] 1
Department of Mechanical Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad 826004, India
2
Department of Mechanical Engineering, JSS Academy of Technical Education, Noida 201301, India
3
Department of Mechanical Engineering, Institute of Engineering and Technology, Dr. A.P.J. Abdul Kalam Technical University, Uttar Pradesh, Lucknow 226021, India
RPMEDM Rotary powder mixed electrical discharge machining SR Surface roughness Ton Pulse on time Toff Pulse off time TWR Tool wear rate TR Tool rotation
1 Introduction In the present age of technological development, EDM has been established as a key unconventional machining process to deal with hard to cut materials irrespective of their hardness. Due to its potential to produce complex shape parts accurately and precisely, the process is widely used in mold and die making, aerospace industry, automobile industry and in medical applications
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