Abstract
The objective of this research focused on the sustainability issues of Electrical discharge Machining (EDM) machining for a non-conductive ceramic material. In this study a thermo-electrical model has been developed for evaluating the feasibility of the EDM process by considering various environment friendly dielectric liquid. Low removal rate, high power consumption, and dependency on conventional fuels (EDM oil as a dielectric liquid) are some premier issues that keep the sustainability index of EDM process low. Silicon carbide ceramic (SiC) has an extensive application in aviation and bio-medical industry. For that a precisizedly machining surface is being needed which can be achieved easily by EDM process. But as it is an electrically insulted material it is difficult to machine it by EDM for which Carbon Nano-tube has been added in to SiC base material to machine it by EDM with enhanced mechanical properties. In this study a comparative analysis has been performed in between the Pongamia-pinnata seed oil, bio-diesel and conventional (EDM oil) system with the help of electro thermal modelling which has been done by COMSOL multiphysics software. The effect of dielectric properties on the performance measures such as Material removal rate (MRR) and Overcut (OC) has been investigated. From the analysis it can be concluded that Bio-diesel based dielectric can be used to achieve high MRR (3.8 mm 3 /min) with high Over Cut (6.7%). An optimized setting of input parameters has been predicted (5A current, 70 V voltage, 25µS pulse-On time, Bio diesel as dielectric and 50µS pulse-off time) by composite desirability approach. The confirmation test has also been conducted which shows 5% deviation from the experimentation result.
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