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EDM is a special type of non-traditional machining technique in which material removal takes place due to repeated electrical discharges at short intervals in the presence of a dielectric medium. It is used in high precision machining of all types of conductive materials such as metals, metallic alloys, graphite and even some ceramic materials. In EDM, the main output parameters are the material removal rate (MRR), electrode wear rate (EWR), and surface roughness ( R a ). It is generally desirable to obtain the maximum MRR with minimum EWR with good surface finish. The dielectrics play a vital role in machining. Even though EDM process has been traditionally used in die sinking industry mostly for machining hard materials, lighter materials like Ti alloy are machined more recently. In some cases, components made out of soft metals like Aluminium alloys are machined in EDM due to the intricacy of profiles, blind prismatic holes and inaccessible areas by other machining methods. This paper aims to investigate the effect of using different dielectrics, viz., biodiesel, transformer oil and kerosene on the material removal rate, electrode wear and surface roughness in EDM. Based on Taguchi’s design of experiments, machining were carried out on Aluminium Alloy 6063 specimens using a die-sinking EDM machine fitted with a copper electrode. The results show that the biodiesel as a dielectric has better performance in MRR, EWR and surface finish in comparison with kerosene and transformer oil. However, performance sustainability and the environmental effect of biodiesel have to be studied.

The electrochemical micromachining (ECMM) system is a modern equipment well thought out as the phenomenon of conventional electrochemical machining (ECM) system in microscale. The ECM system and ECMM system are similar, but the practice method and mechanism involved in the ECM system are analogous to those of the ECMM system, i.e., the differences in machining conditions and machining performance give rise to a factor called the scale effect. In this paper, ECMM has been applied with the advantageous concept called scale effect. Single factor experiments are conducted in which voltage, duty ratio, and tool feed rate are considered as the input factors for the exploration of the different grades of scale effect through the material removal rate, circularity, and overcut. The scale effects that occurred during machining are found using the similarity precision of the micro- and macrosystems based on the similarity theory. Quantitative evaluation of the scale effects is done for the ECMM process. The evaluation showed greater similarity precision indicating a larger significant scale effect. The output values of MRR, circularity, and overcut were normalized which also showed a positive scale effect. The research on scale effects delivers benefits in engineering such as optimizing the processing parameters involved and improving the machining performances of ECMM.

Electrical discharge machining is a non-traditional machining processes in which it is based upon thermal and electrical energy source as an interval energy pulse discharge in-between the work piece and tool electrode so as to remove the material. A systematical investigation of melting and vaporising of aluminium to find the output responses such as Material removal rate (MRR), Electrode wear rate (Ra), and Surface finish (EWR) in EDM using two different dielectrics was conducted as experimental work. The working fluids are Polyethylene glycol (PEG 600) and kerosene. It is the hour of need to get the maximum MRR and surface finish with minimum EWR for any material. The paper focuses on the effect of polymer based dielectric machining the aluminium alloy EDM. The dielectrics enact a great role in production and its influence on environmental aspects should also be considered. These dielectric fluids are used in machining an aluminium alloy 6063 using copper electrode and they are compared for their MRR, EWR, and Ra. Taguchi method is used for analysing the results of two different dielectrics that carried with the help of Minitab software.