Electric discharge machining of hybrid composite with bio-dielectrics for sustainable developments

Abstract

ABSTRACT The hybrid composite (Al-SiC-Ni) has a wide range of applications due to its high strength-to-weight ratio and exceptional mechanical and wears resistance properties. Electric Discharge Machining (EDM) is a common method for machining high-strength composites. However, one significant challenge associated with EDM is the emission of harmful fumes caused by the thermal cracking of hydrocarbon-based dielectrics, as well as the rate of material removal, both of which impact process productivity. However, no research has been conducted on the effect of non-edible biodiesel-based bio-dielectrics on the EDM of hybrid composites (Al-SiC-Ni). As a result, the primary goal of this research is to assess the environmental effects of machining. This study specifically investigates the impact of four types of non-edible biodiesel-based bio-dielectrics on key EDM process output parameters such as material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The EDM performance of the hybrid composite (Al-SiC-Ni) was compared to that of three electrode materials (copper, brass, and graphite) and four bio-diesel-based bio-dielectrics such as Neem biodiesel (NBD), Jatropha biodiesel (JBD), Pongamia biodiesel (PBD), and Polanga biodiesel (POBD). From investigation, it has been observed that the maximum value of material removal rate (MRR) for POBD using a graphite electrode was 18.54 mg/min, which was 58.5% higher than the MRR for JBD using a brass electrode (7.17 mg/min). And it was found that the MRR with POBD was 108.15% higher than with kerosene oil. The graphite as mentioned above electrode obtains its smoothest surface under POBD. This roughness value is 77.41% lower than the JBD value obtained. Tool wear is observed lowest in the brass electrode in conjunction with the JBD. It is 68.88% lower than the TWR value obtained with PBD using the same electrode material. The results indicated that biodiesel derived from non-edible oils could be a promising dielectric for the future of the EDM process.