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Green manufacturing: a comparative study of renewable dielectrics in the EDM process

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Abstract

Electrical discharge machining (EDM) is a nontraditional processing technology that can be used to process materials with a high melting point, high strength, high hardness and low brittleness. Kerosene, as a common dielectric, produces aerosol and toxic gas at high temperatures, which seriously affects the health of operators and air quality. In this study, edible vegetable oils such as sunflower oil, rapeseed oil and peanut oil were used as dielectric to improve the sustainability of EDM. The Taguchi method was used to design experiments, and the effects of vegetable oils with different viscosities on machinability during EDM were discussed from the perspective of mechanism. The machinability was evaluated with the material removal rate (MRR), energy efficiency per unit volume (EEV) and surface roughness (Ra). In addition, the debris diameters of different vegetable oils after processing were studied by using a super depth-of-field optical microscope. The results showed that the MRR of rapeseed oil was 28.9% higher than that of sunflower oil and 25% higher than that of peanut oil. In terms of the MRR, Ra and EEV, rapeseed oil also had obvious advantages because of its high viscosity. In addition, because of the high viscosity of rapeseed oil, the distribution proportion of large fragments was obviously larger than that of the other two oils. The proportion of debris larger than 35 μm in rapeseed oil was 8.21% and that of sunflower oil was only 2.79%. Therefore, vegetable oils can be used instead of a kerosene dielectric to improve the sustainability of EDM and to realize green manufacturing.

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Acknowledgments

This research is supported by Science and Technology Research Project of Henan Province under Grant No. 222102220011, and Local Innovative and Research Team Project of Guangdong Pearl River Talents Program under Grant No. 2017BT01G167. In addition, this research is also supported by the Key Scientific Research Project for Henan Province Higher School of China under Grant No. 21A460034.

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Authors and Affiliations

  1. Henan Key Lab of Intelligent Manufacturing of Mechanical Equipment, Zhengzhou University of Light Industry, Zhengzhou, 450002, China

    Wuyi Ming, Chen Cao, Zhuobin Xie, Yingjie Xu, Zhiwen Jiang, Xiaoke Li, Kun Liu, Xudong Guo & Liwei Li

  2. School of Vehicle and Automation, Guangzhou Huaxia vocational College, Guangzhou, 510900, China

    Xuewen Liu

  3. Guangdong HUST Industrial Technology Research Institute, Guangdong Provincial Key Laboratory of Digital Manufacturing Equipment, Dongguan, 523808, China

    Jie Yuan

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  1. Wuyi Ming
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Ming, W., Cao, C., Xie, Z. et al. Green manufacturing: a comparative study of renewable dielectrics in the EDM process. J Braz. Soc. Mech. Sci. Eng. 44, 580 (2022). https://doi.org/10.1007/s40430-022-03867-3

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