Green and Sustainable Experimental Investigations on Superni 909 Using Electrical Discharge Machining

Electrical Discharge Machining (EDM) is an unconventional method used for machining superalloys. These alloys have been widely used in nuclear, aerospace, jet, rocket, turbine, and petroleum plants, among other applications. Despite many advantages, the EDM process has a few disadvantages. It consumes a lot of energy, produces hazardous emissions, has a slow material removal rate, generates toxic dielectric, and increases manufacturing costs. To reduce the machining cost and provide a safe environment, this paper reports the study of using different compositions of Al2021 + Cu tool and using used gear oil and vegetable oil as a dielectric medium in the shaping of superalloy superni 909. The results of different input parameters viz., current, pulse-on-time, pulse-off-time, voltage, and tool on responses material removal rate and electrode wear rate are investigated. The result shows that these alternate electrodes and dielectrics could be used for sustainable EDM processes.