Approach towards green manufacturing in Maglev EDM using different biodegradable dielectrics at variable discharge conditions

Abstract

The urge to implement eco-friendly approach for modern manufacturing techniques has assisted in eliminating the hazardous effect of the undesirable byproducts released into the atmosphere. In electro-discharge machining (EDM) process, the hydrocarbon oil degradation releases various toxic gases and non-biodegradable residuals as byproducts. Several bio-dielectrics have been implemented to overcome such setbacks as an economical replacement to conventional hydrocarbon oil dielectrics. The current research demonstrates a green Maglev EDM operation on Ti-6Al-4V alloy using neem oil and canola oil as bio-dielectrics compared with EDM oil. Maglev EDM utilizes novel bipolar linear self-servo strategy for tool positioning which generates consistent machining stability by unique magnetic repulsive force balance action. The performance characteristics of all the dielectrics have been examined through machining rate (MR), tool wear rate (TWR), consumed specific energy (SE), area roughness parameters and surface morphology. The results were compared for respective bio-dielectric at variable discharge voltages (VD) i.e. 22 V, 25 V and 28 V, whereas the discharge current (ID) varied within (220-250 mA). The performance assessment depicts (25 to 28) % lower SE consumption in neem oil and (35 to 37)% in canola oil as compared to EDM oil. The surface morphology assessment portrays lower deformities and better uniformity using bio-dielectrics with huge potential for selective surface modification.