Abstract
The technological advancements in the manufacturing industries frequently require the precise machining of hard-to-cut materials with a high degree of accuracy, especially for Ni-based superalloys. The applications and attributes of the said materials’ category justify the use of the electric discharge machining (EDM) process. However, there is a strong need to make this process sustainable and eco-friendly considering the rapid scarcity of resources. Since the conventional dielectric (say kerosene) used in EDM poses serious health concerns and fails in terms of sustainable production specifically in EDM of Inconel (IN) 600. At present, no significant work is available on the experimental investigation in EDM of IN600 by varying powder concentration (Cp: 0, 0.5, 1, and 1.5) g/100 ml and electrode type (ET: Al, brass, Cu, and graphite) using biodegradable dielectric to study the machining performance in four different aspects. For instance, material removal rate (MRR) accounts for the productivity aspect, specific energy consumption (SEC) determines the power consumed, electrode wear rate (EWR) depicts the cost consideration, and surface roughness (SR) represents the quality perspective. The responses defined herein explicitly help to ensure sustainable production. A percent improvement of 12.75% in MRR was found in comparison to the published work in EDM of IN600 using kerosene dielectric. It has also been revealed that the addition of Cu powder in the concentration of 1.5 g/100 ml has raised the MRR to 25.53%. The electrode of graphite has proved to be the best choice for all the defined responses considering the sustainable production of IN600. The optimal settings have been developed and validated that warrant an increase of 11.79% in MRR along with a reduction in SEC (4.23%), EWR (6.935%), and SR (7.20%), respectively. As a result, the cumulative effect of all the said measures leads to a more sustainable manufacturing system.
Similar content being viewed by others
Data availability
All the available data is already contained in this paper.
References
Rehman M, Khan SA, Naveed R (2020) Parametric optimization in electric wire discharge machining of DC53 steel using gamma phase coated wire. J Mech Sci Technol 34:1–7. https://doi.org/10.1007/s12206-020-05
Khan SA, Rehman M, Farooq MU et al (2021) A detailed machinability assessment of DC53 steel for die and mold industry through wire electric discharge machining. Metals (Basel) 11:1–18. https://doi.org/10.3390/met11050816
Singh J, Sharma RK (2016) Assessing the effects of different dielectrics on environmentally conscious powder-mixed EDM of difficult-to-machine material (WC-Co). Front Mech Eng 11:374–387. https://doi.org/10.1007/s11465-016-0388-8
Dhananchezian M (2021) Influence of variation in cutting velocity on temperature, surface finish, chip form and insert after dry turning Inconel 600 with TiAlN carbide insert. Mater Today Proc 46(17):8271–8274. https://doi.org/10.1016/j.matpr.2021.03.250
Pavan C, Sateesh N, Subbiah R (2020) Taguchi analysis on machinability of Inconel 600 using copper, brass, and copper tungsten electrodes in EDM. Mater Today Proc. https://doi.org/10.1016/j.matpr.2020.02.113
Ishfaq K, Rehman M, Khan AR, Wang Y (2022) A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants. Rapid Prototyp J 28:525–545. https://doi.org/10.1108/RPJ-03-2021-0060
Surekha B, Sree Lakshmi T, Jena H, Samal P (2021) Response surface modelling and application of fuzzy grey relational analysis to optimise the multi response characteristics of EN-19 machined using powder mixed EDM. Aust J Mech Eng 19:19–29. https://doi.org/10.1080/14484846.2018.1564527
Tiwary AP, Pradhan BB, Bhattacharyya B (2019) Influence of various metal powder mixed dielectric on micro-EDM characteristics of Ti-6Al-4 V. Mater Manuf Process 34:1103–1119. https://doi.org/10.1080/10426914.2019.1628265
Chakraborty S, Mitra S, Bose D (2020) Experimental investigation on enhancing die corner accuracy during powder mixed wire EDM of Ti6Al4V. Mater Today Proc 38:3097–3102. https://doi.org/10.1016/j.matpr.2020.09.491
Ramesh S, Jenarthanan MP (2021) Optimizing the powder mixed EDM process of nickel based super alloy. Proc Inst Mech Eng Part E J Process Mech Eng 0:1–12. https://doi.org/10.1177/09544089211002782
Bains PS, Sidhu SS, Payal HS, Kaur S (2019) Magnetic field influence on surface modifications in powder mixed EDM. Silicon 11:415–423. https://doi.org/10.1007/s12633-018-9907-z
Salem A, Hegab H, Kishawy HA (2021) An integrated approach for sustainable machining processes: assessment, performance analysis, and optimization. Sustain Prod Consum 25:450–470
Haque R, Sekh M, Kibria G, Haidar S (2021) Comparative study of parametric effects on the performance of simple and powder mixed EDM using aluminium and graphite powder on Inconel X750 alloy. Mater Today Proc. https://doi.org/10.1016/j.matpr.2021.03.419
Peças P, Henriques E (2008) Effect of the powder concentration and dielectric flow in the surface morphology in electrical discharge machining with powder-mixed dielectric (PMD-EDM). Int J Adv Manuf Technol 37:1120–1132. https://doi.org/10.1007/s00170-007-1061-5
Bhattacharya A, Batish A, Singh G, Singla VK (2012) Optimal parameter settings for rough and finish machining of die steels in powder-mixed EDM. Int J Adv Manuf Technol 61:537–548. https://doi.org/10.1007/s00170-011-3716-5
Nagabhooshanam N, Baskar S, Anitha K, Arumugam S (2021) Sustainable machining of Hastelloy in EDM using nanoparticle-infused biodegradable dielectric fluid. Arab J Sci Eng 46:11759–11770. https://doi.org/10.1007/s13369-021-05652-1
Ming W, Xie Z, Cao C et al (2022) Research on EDM performance of renewable dielectrics under different electrodes for machining SKD11. Crystals 12:291. https://doi.org/10.3390/cryst12020291
Yadav NK, Singh L, Lal S (2020) Experimental investigation for sustainable electric discharge machining with Pongamia and Jatropha as dielectric medium. Adv Mater Process Technol 00:1–20. https://doi.org/10.1080/2374068X.2020.1860499
da Silva LR, dos Santos FV, de Morais HLO, Calado CR (2022) Evaluation of the use of vegetable oils in the grinding of AISI 4340 steel. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-022-08727-x
Davoren B, Sacks N, Theron M (2020) Laser engineered net shaping of WC-9.2wt%Ni alloys: a feasibility study. Int J Refract Met Hard Mater 86:105136. https://doi.org/10.1016/j.ijrmhm.2019.105136
Shah ZH, Tahir QA (2011) Dielectric properties of vegetable oils. J Sci Res 3:481–492. https://doi.org/10.3329/jsr.v3i3.7049
Khan MI, Chhetri AB, Islam MR (2007) Analyzing sustainability of community-based energy technologies. Energy Sources, Part B 2:403–419
Valaki JB, Rathod PP (2016) Assessment of operational feasibility of waste vegetable oil based bio-dielectric fluid for sustainable electric discharge machining (EDM). Int J Adv Manuf Technol 87:1509–1518. https://doi.org/10.1007/s00170-015-7169-0
Ishfaq K, Asad M, Harris M et al (2022) EDM of Ti-6Al-4 V under nano-graphene mixed dielectric: a detailed investigation on axial and radial dimensional overcuts. Nanomater 12:432
Ishfaq K, Maqsood MA, Anwar S et al (2022) EDM of Ti6Al4V under nano-graphene mixed dielectric: a detailed roughness analysis. Int J Adv Manuf Technol 120:7375–7388. https://doi.org/10.1007/s00170-022-09207-y
Satyanarayana K, Mounika M, Kiran KR (2021) Experimental studies and optimization of WEDM process in machining of Inconel 600 using zinc wire. Mater Today Proc 44:2431–2434
Kumar S, Kumar S (2020) Experimental investigation on surface characteristics of nickel-based super alloy Inconel-600 in powder mixed electric discharge machining by using response surface methodology. Adv Eng Mater Sel Proc FLAME 2020:281
Ishfaq K, Rehman M, Wang Y (2022) Investigation of dimensional deviation in biodegradable dielectric-based powder-mixed electric discharge machining of Ni-based superalloy. J Mech Sci Technol 36:4153–4159. https://doi.org/10.1007/s12206-022-0733-2
Ishfaq K, Maqsood MA, Anwar S et al (2022) Analyzing micromachining errors in EDM of Inconel 600 using various biodegradable dielectrics. J Brazilian Soc Mech Sci Eng 44:1–12
Singh B (2021) Influences of powder mixed dielectric fluid on machining characteristics of EDM processed parts: a review. IOP Conf Ser Mater Sci Eng 1116:012099. https://doi.org/10.1088/1757-899x/1116/1/012099
Ishfaq K, Rehman M, Wang Y (2022) Toward the targeted material removal with optimized surface finish during EDM for the repair applications in dies and molds. Arab J Sci Eng. https://doi.org/10.1007/s13369-022-07006-x
Jeevamalar J, Kumar SB, Ramu P et al (2021) Investigating the effects of copper cadmium electrode on Inconel 718 during EDM drilling. Mater Today Proc 45:1451–1455. https://doi.org/10.1016/j.matpr.2020.07.416
Yadav A, Singh Y, Singh S, Negi P (2021) Sustainability of vegetable oil based bio-diesel as dielectric fluid during EDM process - a review. Mater Today Proc 46:11155–11158. https://doi.org/10.1016/j.matpr.2021.01.967
Ehsan S, Khan SA, Rehman M, Ehsan S, Khan SA, R M (2021) Defect-free high-feed milling of Ti-6Al-4 V alloy via a combination of cutting and wiper inserts. Int J Adv Manuf Technol 114:641–653. https://doi.org/10.1007/s00170-021-06875-0
Ishfaq K, Zahoor S, Khan SA et al (2021) Minimizing the corner errors (top and bottom) at optimized cutting rate and surface finish during WEDM of Al6061. Eng Sci Technol an Int J. https://doi.org/10.1016/j.jestch.2021.01.008
Payla A, Chopra K, Mussada EK (2019) Investigations on power consumption in WEDM of EN31 steel for sustainable production. Mater Manuf Process 34:1855–1865. https://doi.org/10.1080/10426914.2019.1683577
Ishfaq K, Naveed R, Maqsood MA, Rehman M (2022) Analyzing laminated electrode(s) performance for the EDM of microchannel(s) in Al(6061). Int J Adv Manuf Technol 123:2941–2958. https://doi.org/10.1007/s00170-022-10360-7
Hassan A, He YL, Rehman M et al (2022) Machinability investigation in electric discharge machining of carbon fiber reinforced composites for aerospace applications. Polym Compos 43:7773–7788. https://doi.org/10.1002/pc.26878
Ehsan S, Rehman M, Mughal MP et al (2022) Machinability investigations through novel controlled flushing characteristics in wire electric discharge machining of M42 high-speed steel. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-022-08786-0
Tosun N, Cogun C, Tosun G (2004) A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method. J Mater Process Technol 152:316–322. https://doi.org/10.1016/j.jmatprotec.2004.04.373
Zahoor S, Azam HA, Mughal MP et al (2021) WEDM of complex profile of IN718: multi-objective GA-based optimization of surface roughness, dimensional deviation, and cutting speed. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-021-06916-8
Dewan PR, Kundu PK, Phipon R (2020) Powder mixed electric discharge machining–a review. In: AIP Conference Proceedings. AIP Publishing LLC 2273(1):50075. https://doi.org/10.1063/5.0025268
Joshi AY, Joshi AY (2019) A systematic review on powder mixed electrical discharge machining. Heliyon 5:e02963
Maradia U, Boccadoro M, Stirnimann J et al (2015) Electrode wear protection mechanism in meso–micro-EDM. J Mater Process Technol 223:22–33. https://doi.org/10.1016/j.jmatprotec.2015.03.039
Rehman M, Yanen W, Mushtaq RT et al (2022) Additive manufacturing for biomedical applications: a review on classification, energy consumption, and its appreciable role since COVID-19 pandemic. Prog Addit Manuf. https://doi.org/10.1007/s40964-022-00373-9
Ming W, Zhang S, Zhang G et al (2022) Progress in modeling of electrical discharge machining process. Int J Heat Mass Transf 187:122563. https://doi.org/10.1016/j.ijheatmasstransfer.2022.122563
Taherkhani A, Ilani MA, Ebrahimi F et al (2021) Investigation of surface quality in Cost of Goods Manufactured (COGM) method of μ-Al2O3 powder-mixed-EDM process on machining of Ti-6Al-4V. Int J Adv Manuf Technol 116:1783–1799. https://doi.org/10.1007/s00170-021-07573-7
Mali HS, Kumar N (2016) Investigating feasibility of waste vegetable oil for sustainable EDM. In: Proceedings of all india manufacturing technology design and research conference, pp 405–410
Yunus Khan M, Sudhakar Rao P, Pabla BS (2019) Investigations on the feasibility of Jatropha curcas oil based biodiesel for sustainable dielectric fluid in EDM process. Mater Today Proc 26:335–340. https://doi.org/10.1016/j.matpr.2019.11.325
Mohanty A, Talla G, Gangopadhyay S (2014) Experimental investigation and analysis of EDM characteristics of Inconel 825. Mater Manuf Process 29:540–549. https://doi.org/10.1080/10426914.2014.901536
Talla G, Gangopadhyay S, Biswas CK (2016) Effect of powder-suspended dielectric on the EDM characteristics of Inconel 625. J Mater Eng Perform 25:704–717. https://doi.org/10.1007/s11665-015-1835-0
Author information
Authors and Affiliations
Contributions
Kashif Ishfaq: data collection, supervision, conceptualization; Mudassar Rehman: writing—original draft, conceptualization, data collection, investigation, technical writing, softwares for data analysis, visualization, resources, editing, and review.
Corresponding author
Ethics declarations
Ethics approval
Authors confirm that they have abided by the publication ethics, state the originality of this work which has not been used anywhere else for publication.
Consent for publication
Authors allow the publishing of this work in this prestigious journal.
Competing interests
Authors declare no conflict of interest or personal relationships that could have appeared to influence this work.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Ishfaq, K., Rehman, M. Machinability investigation using Cu-mixed biodegradable dielectric for eco-friendly/sustainable machining of Ni-based superalloy. Int J Adv Manuf Technol 125, 2243–2264 (2023). https://doi.org/10.1007/s00170-023-10836-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-10836-0