Feasibility study of biodiesels in mu ED milling of Ti-6Al-4V under different parametric conditions

摘要

Dielectric fluid is an essential parameter in the well-established mu ED milling process for attaining the high metal removal rate and surface finish. However, using hydrocarbon oil as a dielectric fluid for mu EDM causes serious health issues, namely skin cancer, allergy and breathing problems for operators. This study aimed to assess the feasibility of coconut and Karanja biodiesels during mu ED milling of Ti-6Al-4V alloy under different settings of voltage, spindle speed and capacitance. The morphology of the machined surface with various dielectric fluids was analyzed by using SEM. The maximum MRR and minimum EWR are observed with EDM oil compared with the considered dielectric fluids. Karanja biodiesels offered a larger crater followed by coconut biodiesel and EDM oil. Microhardness is substantially increased with EDM oil due to the disintegration of hydrocarbon oil. The maximum recast layer thickness is observed with Karanja biodiesel due to incomplete removal of debris particles from machining region. High surface finish is obtained with EDM oil due to uniform distribution of heat energy over machining region. Breakdown voltage of coconut and Karanja biodiesels is 0.73 and 1.3 times higher, respectively, than that of EDM oil. The crater size increased by 19.1 and 28 with coconut and Karanja biodiesels, respectively. Among the biodiesels, the coconut biodiesel followed closely with EDM oil in all considered response indicators. Thus, it can be a real alternative to hydrocarbon oil. It is proposed that the biodiesels can provide a safer environment for the human operator at the cost of machining efficiency as compared to EDM oil.