Journal of Computational & Applied Research in Mechanical Engineering (JCARME)

Articles in Press

Document Type : Research Paper

Authors

Haneen Lateef ¹
Saad Mahmood Ali ²

¹ Production Engineering and Metallurgy Department. University of Technology, Baghdad, 19006, Iraq

² Biomedical Engineering Department, University of Technology Baghdad, 19006, Iraq

10.22061/jcarme.2025.11417.2503

Abstract

The objective of this study is to examine how the input parameters of wet-EDM, near-dry (ND-EDM), and NDPM-EDM affect the output performances of the newly fabricated metal matrix composites (MMCs) of aluminum Al-7075/MSGNP nanocomposites produced by the stir-casting. Air, Ar, mix (Ar+N2), and Ferron gases were included in the current study, which used vegetable oil as a dielectric medium. Additionally, Kaolinite Nano powders were employed as an additive in ND-EDM studies. The data obtained indicate that the greatest MRR attained in the ND-EDM process was 29.425 mm3/min when vegetable oil and Freon gas were used. In the NDPM-EDM, the highest achieved MRR obtained using the Freon gas reached 15.468 (used 800 µsec, 5% Al2SiO2(OH)4). The obtained result is higher than the highest value obtained when using vegetable oil alone by 209.37%. The lowest achieved EWR obtained using the Freon gas reached 0.003 with the vegetable oil + 5% and 10% Al2SiO2(OH)4). The lowest achieved SR for all the implemented experiments, was obtained with used the Freon additive gas to dielectric, reached 4.797 µm (used 5% Al2SiO2(OH)4). The SR value obtained is 19.88% lower than the minimum value achieved when using only vegetable oil. The SEM study showed that the average thickness of the recast white layer was significantly reduced when using the ND-EDM approaches compared to the standard wet-EDM method. The decrease percentages for introducing air, Ar, mix (Ar-N2), and Freon gases into the vegetable oil dielectrics for ND-EDM were 108.17%, 165.51%, 630.26%, and (∞).

Graphical Abstract

Keywords

Main Subjects

Manufacturing Processes

References

[1] Pandey, S. Singh, “Current research trends in variants of electrical discharge machining: a review. Int. J. of Eng. Sci. and Tech. Vol. 2, pp. 2172-2191, (2010).

[2] Grzesik, “Advanced machining processes of metallic materials: theory, modeling, and applications” Elsevier, (2008). h

[3] P. Groover, Fundamentals of modern manufacturing: materials processes, and systems. John Wiley & Sons, (2007).

[4] M. Ali “Influence of electrodes and parameters on micro-edm drilling performances of 304l stainless steel" 2nd International Conference on Engineering Technology and its Applications (IICETA), Al-Najef, Iraq, pp. 55-60, (2019).

[5] Paramashivan, J. Mathew, S. Mahadevan, “Mathematical modeling of aerosol emission from die-sinking electrical discharge machining process”, Appl. Math. Modell., Vol. 36, pp. 1493-1503, (2012).

[6] Abrol, V. K. Singla, “Study on optimization and machining characteristics of electric discharge machining using powder suspension dielectric fluids”, A thesis, Thapar University, (2012).

[7] A. Abukhshim, P. T. Mativenga, M. A. Sheikh, “Heat generation and temperature prediction in metal cutting: a review and implications for high-speed machining” Int. J. Mach. Tools Manuf., Vol. 46, pp. 782-800, (2006).

[8] Al-Khazraji, S. Amin and S. M. Ali “The effect of sic powder mixing electrical discharge machining (PMEDM) on fatigue life of aisi d2 die steel”, Eng. Sci. Technol. Int. J., Vol.19, pp. 1400-1415, (2016).

[9] Srivastava, M. Vishnoi, M. T. Gangadhar, V. Kukshal, “An insight on powder mixed electric discharge machining: a state-of-the-art review”, Proc. Inst. Mech. Eng., Part B: J. Eng. Manuf., Vol. 237, No. 5, pp. 657-690, (2023).

[10] A. Olatz, A. S. Jose, and I. Borja, “Approaches for improvement of edm performance and for the understanding of electrode wear phenomena”, Precis. Eng., Vol. 49, pp. 33-40 (2018).

[11] El-Hofy, H. Youssef, “Environmental hazards of nontraditional machining”, Proc. of the 4th IASME/ WSEAS Int. Conf. on Energ. & Env. (EE’09), Cambridge, Vol. 24, No. 26, pp. 140–145, (2009).

[12] Rugbani, “Predictive model for diameter control of polysulfone hollow fibers produced by dry-jet wet spinning”, J. comput. appl. res. mech. eng. (JCARME), Vol. 13, No.1, pp. 27-38, (2023).

[13] S. Chetan, P. V. Rao, “Environment-friendly machining of ni–cr–co based super alloy using different sustainable techniques”, Mater. Manuf. Processes, Vol. 31, No. 7, pp. 852–859, (2016).

[14] Mabbu, R. P. Srinivasa, V. P. Madar, “Experimental investigation of edm process parameters by using pongamia pinnata osil blends as dielectric medium”, J. of Comput. & Appl. Res. in Mech. Eng. (JCARME), Vol. 11, No. 1, pp. 47-56, (2021).

[15[ K. Singh, P. M. Pandey, K. K. Singh, M. K. Sharma, “Steps towards green manufacturing through edm process: a review”, Cogent Eng, Vol. 3, No. 1, pp. 1–13, (2016).

[16] Al-Khazraji, S. Amin and S. M. Ali, “Study the effect of the graphite powder mixing electrical discharge machining on creation of surface residual stresses for aisi d2 die steel using design of experiments”, Eng. and Tech. J., Vol.33, Part (A), No.6, pp. 1399-1415, (2015).

[17] Kumar, S. Maheshwari, C. Sharma, N. Beri, “Research developments in additives mixed electrical discharge machining (AEDM): a state of art review”, Mater. Manuf. Process, Vol. 25, No. 10, pp. 1166–1180, (2010).

[18] Shivakoti, G. Kibria, S. Diyaley, B. B. Pradhan, “Multi-objective optimization and analysis of electrical discharge machining process during micro-hole machining of D3 die steel employing salt mixed deionized water dielectric” J. of Comput. & Appl. Res. in Mech. Eng. (JCARME), Vol. 3, pp. 27-39, (2013).

[19] Jose, S. P. Sivapirakasam, M. Surianarayanan, “Analysis of aerosol emission and hazard evaluation of electrical discharge machining (EDM) process”, Industrial Health, Vol. 48, pp. 478-486, (2010).

[20] Dhakar, A. Dvivedi, “Dry and near-dry electric discharge machining processes”, Advanced Manufacturing Technologies. Materials Forming, Mach. and Trib., K. Eds. Gupta, Springer, Cham., pp. 249-266, (2017).

[21] S. Nimbalkar, P. M. T. Shete, “Experimental investigation of machining parameters using solid and hollow electrode for EDM of Ti-6Al-4V”, Int. Res. J. Eng. Technol., Vol. 4, 2345, (2017).

[22] Shukla, K. Sharma, “Assessment of particle size distribution and tensile properties of hybrid epoxy composite reinforced with functionalized graphene and CNT nanofillers”, J. of Comput. & Appl. Res. in Mech. Eng. (JCARME), Vol. 12, No. 1, pp. 1-12, (2022).

[23]D. N. Islama, A. Dasa, S. Jarina, “Experimental Investigation of Mechanical Behavior of CFRP-AA7075-T6 Composite and Finite Element Analysis for Automotive Wheel Rim Application”, Journal of Materials and Engineering, Vol. 02, Iss. 4, PP. 259-266, (2024).

[24] M. S. Kumar, “Microstructural Evaluation of Al-Al2O3 Composites Processed by Stir Casting Technique”, Journal of Materials and Engineering, Vol. 02, Iss. 4, 267-272, (2024).

[25] Wang, S. Yi, H. Guo, C. Li, S. Ding, “Erosion characteristics of electrical discharge machining using graphene powder in deionized water as dielectric,” Int. J. Adv. Manuf. Technol, Vol. 108, pp. 357-368, (2020).

[26] P. Jahan, P. Kakavand, F. A. Alavi, “A comparative study on micro-electro-discharge-machinedsurface characteristics of Ni-Ti and Ti-6Al-4V with respect to biocompatibility”, Procedia Manuf., Vol. 10, pp. 232–242, (2017).

[27] A. Pathan, A. Kumar, and V. J. Badheka, “Recent advances in electrical discharge machine techniques and machining: a review”, World J. of Adv. Eng. Tech. and Sci, Vol. 12, No. 02, PP. 124–132, (2024).

[28] Rahman, Z. G. Wang, Y. S. Wong, “A review on high-speed machining of titanium alloys”, In Proc. of the 3rd Int. Conf. on Leading Edge Man. in 21st Century, Nagoya, Japan, Vol. 49, pp. 19–28, (2005).

[29] Hassan,” Investigation on surface hardness and microstructure evolution in AA 7075-T651 multi-layered laminate fabricated through friction stir additive manufacturing”, IJMSE, Vol. 20, No. 4, pp. 1-12, (2023).

[30] Hocheng, H. V. Tsai, “Advanced analysis of nontraditional machining”, Springer Science & Business Media, Berlin/Heidelberg, Germany, (2013).

[31] Alidoosti, A. Ghafari-Nazari, F. Moztarzadeh, N. Jalali, S. Moztarzadeh, M. Mozafari, “Electrical discharge machining characteristics of nickel-titanium shape memory alloy based on full factorial design”, J. Intell. Mater. Syst. Struct., Vol. 24, pp. 1546–1556, (2013).

[32] L. Chen, S. F. Hsieh, H. C. Lin, M. H. Lin, J. S. Huang,” Electrical discharge machining of TiNiCr and TiNiZr ternary shape memory alloys”, Mater. Sci. Eng. A, Vol. 445–446, pp. 486–492, (2007).

[33] P. Sandeep, V. R. Vaira, V. Ajay, H. S. Harie, T. S. Vyoma, R. Padmanaban, R. Samuel, P. S. Kumar, “Influence of friction stir processing parameters on the mechanical and corrosion properties of Al-Cu-Li alloy”, IJMSE, Vol. 20, No. 2, pp. 1-11, (2023).

[34] Mustafa, S. Daham, “Investigation of process parameters for T-joint aluminum alloy 6061-T6 with nanocomposites material friction stir welding based on the Taguchi method', J. of Comput. & Appl. Res. in Mech. Eng. (JCARME), Vol. 11, No. 1, pp. 101-111, (2021).

[35] Mustu, B. Demir, F. Aydin, H. Gürün, “An investigation of the PMEDM processing and surface characterizations of az61 matrix composites via experimental and optimization methods”, Mater. Chem. Phys., Vol. 300, 127526, (2023).

[36] A. Ghulam and A. F. Ibrahim, “Enhancing electrical discharge machining performance by mixing nano chromium trioxide powder with soybean dielectric to machine inconel 718 alloy”, Adv. Sci. Technol. Res. J., Vol. 18, No. 2, pp. 129-142, (2024).

[37] Amirkhanlou, B. Niroumand, “Synthesis and characterization of 356-SiCp composites by stir casting and compocasting methods”, Trans. Nonferrous. Met. Soc. Vol. 20, pp. 788-793, (2010).

[38] Dhakar, A. Dvivedi, “Parametric evaluation on near-dry electric discharge machining”, Mater. Manuf. Process, Vol. 31, Vol. 4, 413–421, (2016).

[39] K. Singh, P. M. Pandey, K. K. Singh, “Experimental investigations into the performance of EDM using argon gas-assisted perforated electrodes”, Mater. Manuf. Process, Vol. 32, No. 9, PP. 940–951, (2017).

[40] K. Gupta, A. Dvivedi, P. Kumar, “Effect of pulse duration on quality characteristics of blind hole drilled in glass by ECDM”, Mater. Manuf. Process, Vol. 31, No. 13, pp. 1740–1748, (2016).

[41] Bai, Q. H. Zhang, T. Y. Yang, J. H. Zhang, “Research on material removal rate of powder mixed near dry electrical discharge machining”. Int. J. Adv. Manuf. Technol. Vol. 68, pp. 1757–1766 (2013).

[42] Upadhyay, M. L. Aggrawal, P. M. Pandey, “Performance analysis of magnetorheological fluid-assisted electrical discharge machining. mater”, Manuf. Process. Vol. 33, No. 11, pp. 1205–1213, (2018).

[43] D. Xames, F. K. Torsha, and F. Sarwar, "ANN-based performance prediction of electrical discharge machining of ti-13nb-13zr alloys", World J. Eng, Vol. 21 No. 2, pp. 217-227, (2024).

[44] Prakash, H. K. Kansal, B. S. Pabla, S. Puri, “Experimental investigations in powder mixed electric discharge machining of ti–35nb–7ta–5zrβ-titanium alloy”, Mater. Manuf. Process, Vol. 32, No. 3, PP. 274–285, (2017).

[45] P. Agrawal, N. Somani, and N. K. Gupta, “A systematic review on powder-mixed electrical discharge machining (pmedm) technique for machining of difficult-to-machine materials”, Innovation Emerging Technol., Vol. 11, 2440002, PP. 1-11, (2024).

[46] F. Tzeng, and C. Y. Lee, “Effects of powder characteristics on electro-discharge machining efficiency” Int. J. Adv. Manuf. Technol. Vol. 17, pp. 586–592 (2001).

[47] Kumar, M. Gupta, V. Kunar, “Experimental investigation of surface crack density and recast layer thickness of WEDMed Inconel 825”, J. of Comput. & Appl. Res. in Mech. Eng. (JCARME), Vol. 11 No.1, pp. 205-216, (2021).

[48] Pragadish and M. Pradeep Kumar, “Surface Characteristics Analysis of Dry EDMed AISI D2 Steel Using Modified Tool Design”, JMST, Vol. 29, No. 4, pp. 1737-1743, (2014).

[49] Abdudeen, J. E. Abu Qudeiri, A. Kareem, T. Ahammed, A. Ziout, “Recent advances and perceptive insights into powder-mixed dielectric fluid of EDM”, Micromachines, Vol. 11, pp. 754.

[50] Kumar, A. Batish, R. Singh and T. P. Singh, “A hybrid Taguchi-artificial neural network approach to predict surface roughness during electric discharge machining of titanium alloys,” JMST, Vol. 28, No. 7, pp. 2831-2844, (2014).

[51] Paswan, A. S. Dube, S. Shankar, “Exploring powder mixed electrical discharge machining (PMEDM)” AIP Conf. Proc. Vol. 3178, No. 1, 070011, (2024)

[52] Q. Li, W. S. Zhao, S. C. Di, et al., “Experimental study on electrical discharge machining in gas”, JME, Vol. 42, No. 203, (2006).

[53] Liqing and S. Yingjie, “Study of dry EDM with oxygen-mixed and cryogenic cooling approaches “, Procedia CIRP, Vol. 6, pp. 344–350, (2013).

[54] Jeavudeen, H. S. Jailani, and M. Murugan, “Powder additives influence on dielectric strength of EDM fluid and material removal” Int. J. Mach. Mach. Mater., Vol. 22, No.1, pp. 47–61, (2020).

Name *

Email Address *

Affiliation *

Comments *

Security Code *

CAPTCHA Image

Journal of Computational & Applied Research in Mechanical Engineering (JCARME)

Articles in Press, Accepted Manuscript
Available Online from 16 July 2025

Files

Share

How to cite

Statistics

Article View: 6
PDF Download: 6