PERFORMANCE EVALUATION AND ECONOMIC ASSESSMENT IN ELECTRICAL DISCHARGE MACHINING OF SS316 USING GRAPHITE POWDER DISPERSED IN BIODEGRADABLE PALM OIL DIELECTRIC

Sunita Sethy, Sudhansu Ranjan Das, Jaydev Rana (), Amit Kumar Behera () and Munish Kumar Gupta
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Sunita Sethy: Department of Mechanical Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India†Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India
Sudhansu Ranjan Das: ��Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India
Jaydev Rana: Department of Mechanical Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India
Amit Kumar Behera: ��Department of Chemical Engineering, Veer Surendra Sai University of Technology, Burla 768018, Odisha, India
Munish Kumar Gupta: �Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska Street, 45-758 Opole, Poland¶Department of mechanical Engineering, Graphic Era (Deemed to be University), Uttrakhand 248002, India

Surface Review and Letters (SRL), 2025, vol. 32, issue 03, 1-17

Abstract: In today’s rapidly evolving manufacturing industry, researchers and engineers are constantly seeking innovative methods to improve machining processes. One such area of interest is the use of electrical discharge machining (EDM) for difficult-to-machine metals like SS316. This research compares the performance and economic aspects of traditional EDM and powder-mixed EDM when machining SS316 using copper electrode. Graphite powder dispersed in biodegradable palm oil is investigated as a dielectric media with the aim of enhancing EDM performance. According to the findings, the analysis of the cutting performance of different machinability aspects revealed that using graphite powder mixed with palm oil as a dielectric in EDM outperformed conventional EDM relating to material removal, surface finish, surface hardness, electrode wear rate and hole overcut. The flushing condition and unique properties of graphite powder and palm oil, such as cooling, and thermal conductivity, contributed to the improved performance observed in EDM processes. These findings highlight the potential of graphite powder mixed with palm oil as a promising alternative dielectric in EDM, offering enhanced machining capabilities and improved surface quality. The total machining expenditure per part under PMEDM (INR 505.50) is lowered by 9.2% than expenditure under conventional EDM (INR 525). The surface microhardness of the machined component attained using graphite powder-mixed EDM is enhanced in comparison to that achieved using standard EDM due to the creation of a carbon-rich re-solidified layer.

Keywords: SS316; EDM; powder-mixed dielectric; machinability; recast layer; economic assessment (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1142/S0218625X24501208

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