Sustainable machining and optimization of machining parameters utilizing different dielectrics in EDM machining of Waspaloy

This study investigates the influence of various dielectric fluids on the performance of Electric Discharge Machining (EDM) in machining Waspaloy, a corrosion-resistant superalloy known for its high hardness and enhanced corrosion resistance. The purpose of this work is to fill the knowledge gap about the machining of Waspaloy using different dielectric fluids by using a Copper-5Graphite (CuGr5) composite tools. Experiments were conducted using a EDM machine with copper graphite composite electrodes and five distinct dielectric fluids, including hydrocarbon oil, kerosene, sunflower oil, used motor oil, and groundnut oil. The effects of key process parameters such as current, voltage, pulse on time, pulse off time, and gap distance on Material Removal Rate (MRR) and Surface Roughness (Ra) were evaluated. Dielectric fluid properties, including viscosity, density, thermal conductivity, and dielectric strength, were comprehensively characterized. Results revealed that MRR increased with current and pulse-on time up to a threshold, beyond which thermal damage reduced efficiency. Sunflower oil demonstrated the most favorable performance, achieving an MRR of up to 0.570 mm³/min and Ra as low as 1.012 μm, attributed to its high dielectric strength (40 kVA), moderate viscosity, and superior thermal conductivity. In contrast, kerosene and hydrocarbon oil, while effective in debris flushing, resulted in inconsistent spark stability and increased surface roughness at higher energy settings due to lower dielectric strength and flash points. Used motor oil and groundnut oil, though sustainable, exhibited higher surface roughness and limited MRR under elevated parameter settings owing to their higher viscosity and lower heat dissipation capabilities. A novel predictive equation for MRR and Ra, integrating dielectric fluid properties and machining parameters, was developed to enhance process optimization. Surface morphology analysis using SEM revealed characteristic features such as craters, recast layers, microcracks, and resolidified debris, highlighting the interplay between thermal, electrical, and mechanical effects during EDM. This research promotes sustainable manufacturing by assessing bio-based and waste-derived dielectric fluids as environmentally responsible alternatives to conventional EDM oil.