Investigations on Performance Enhancement of Eco-Friendly Electrical Discharge Machining using oil based bio dielectric fluid of Oil Hardened Non-Shrinkable Steel – A Review

Mechanical Engineering

OHNS (Oil Hardened Non-Shrinkable Steel) is widely used in range of application in tool and die making industries. OHNS steel is a general purpose steel that is generally used in applications where alloy steels cannot provide sufficient hardness, strength and wear resistance. The electric discharge machining is categorized as thermoelectric process in which the heat energy generated by spark is used to erode material from work piece. In this process, high-frequency electric sparks cause decomposition of the dielectric media, which eventually generates intense temperatures of the order of 8000–12,000 K to melt and vaporize the work material. Uniqueness of the process lies in the fact that the material is removed accurately and precisely at extremely high temperature. Controlled material erosion makes it possible to generate dimensionally and geometrically accurate profiles on difficult-to-cut materials. The present work is about analysis of performance comparison of the electric discharge machining of OHNS steels using Hydrocarbon based oil and eco-friendly bio dielectric. With the consideration of influencing parameters, experiments are conducted with the copper electrode used as the tool and OHNS as the work piece in the machining process. The combination of the gap voltage, gap current settings are selected for maximum material removal rate (MRR), surface roughness (SR), surface crack density, white layer thickness etc. Finally the optimum cutting condition is said to be obtained.

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