Evaluation of technical feasibility and environmental impact of Calophyllum Inophyllum (Polanga) oil based bio-dielectric fluid for green EDM

• Published in: Measurement : journal of the International Measurement Confederation Vol. 159; p. 107744
• Main Authors: Mishra, B.P., Routara, B.C.
• Format: Journal Article
• Language: English
• Published: London Elsevier Ltd 15.07.2020; Elsevier Science Ltd
• Subjects: Aerosol emission rate; Algorithms; Bio-dielectric; Business competition; Dielectrics; EDM electrodes; Emission analysis; Energy conservation; Environmental impact; Feasibility studies; Fire hazards; Green EDM; Green products; Health hazards; Manufacturing; Material removal rate (machining); Oils & fats; Performance evaluation; Process parameters; Process quality; Productivity; Reduction; Surface finish; Surface hardness; Surface layers; Sustainability; Toxic hazards; Wear rate; Wit; Bio-dielectric; Aerosol emission rate; MRR; Ra; Wf j; PBD; min; SH; Sustainability; V; µm; WP; DOF; mg; Green EDM; OM; µs; SR; Productivity; Dmj; RUC; Wft; Dh; gm; ROC; IP; HCD; REWR; Process quality; Dmt; TWR; OFAT; n; Dt; Ton; ASTM; Wij; HRD; SEDM
• ISSN: 0263-2241; 1873-412X
• DOI: 10.1016/j.measurement.2020.107744

[Display omitted] •The research explores new bio-dielectric i.e Calophyllum inophyllum (polanga).•3 productivity & process quality aspects (MRR,TWR,REWR,SR,SH,ROC/RUC) are assessed.•Significant improvement in output responses were found in the comparison process.•Environmental impact with aerosol emission rate for PBD is lower by 17.33% in comparison to HC dielectric.•Current study will be more helpful in opening path for more in-depth research in GREEN EDM. In a global scenario, energy conservation with eco-sustainable manufacturing is a major challenge for engineers. Motivation and stringent implementation of sustainable manufacturing practices is one significant way to insure the green environment for future. Alarming needs at present is innovative green methods of non-conventional manufacturing processes to be globally competitive. So, in the present investigation, authors have assessed the operational feasibility of transesterified Calophyllum Inophyllum (Polanga) based non-edible oil as possible alternative bio-dielectric for EDM applications and compared the response patterns of the new bio-dielectric fluid with hydrocarbon based EDM oil. OFAT (one factor at a time) design algorithm was utilized using peak current, duty cycle, pulse-on time, and gap voltage as control parameters to evaluate the response pattern for material removal rate, electrode wear rate, relative electrode wear ratio, surface texture and aerosol emission rate. The study confirms that Polanga bio-dielectric contributes to higher productivity and better process quality parameters like enhancement in mean MRR by 0.86 times, better surface finish by 16.64%, surface hardness by 6.46% as well as refined microstructure quality as compared to traditional hydrocarbon dielectric. Assessment of environmental impact through aerosol emission rate confirms 17.33% reduction with Polanga bio-dielectric use. Results and performance evaluation reveal that new bio-dielectric fluid can be a primary dielectric choice for green EDM replacing conventional hydrocarbon, water and synthetic based dielectric fluids. Findings also confirms that it can greatly contribute for establishing a family of vegetable-based bio dielectrics in the area of green manufacturing thus removing obstacles like reduction of toxic emissions, operator’s health hazards, fire hazards and enhancement of environmental sustainability in future.