Sustainable electrochemical discharge machining process: Characterization of emission products and occupational risks to operator

Abstract

Electrochemical discharge machining (ECDM) process is prominent machining process for processing of composites, glass, ceramics, and super-alloys. In the recent years, the ECDM process has attained popularity due to its applicability to generate micro-holes, micro-channels on different materials irrespective to their properties. This study presents the various environmental aspects of ECDM process for its transformation to sustainable and green manufacturing. The exhaustive analysis of fume particles generated in ECDM process with their characterization and health impacts has been attempted in the present work. A detailed procedure has been reported to explore the effect of applied voltage and electrolyte concentration on fume mass concentration, fume particles size, particle morphologies, and chemical composition. The morphology of fume particles revealed presence of spherical, irregular, rectangular, and agglomerations shapes. The chemical composition of fume particles indicates presence of metallic toxic and carcinogen elements such as Al, Fe, Cr, Cu, Ti, Ni, etc. The presence of hazardous compounds in the breathing zone was studied using Fourier transform infrared spectroscopy analysis of breathing air. Additionally, occupational risks associated with fumes emission and their control measure has been addressed in this research work.