Energy efficiency and sustainability enhancement of electric discharge machines by incorporating nano-graphite

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Energy efficiency and sustainability enhancement of electric discharge machines by incorporating nano-graphite

Asaad A. ABBAS, Raed R. SHWAISH, Shukry H. AGHDEAB, Waleed AHMED

Abstract. The research paper endeavored to significantly improve the energy efficiency and sustainability of the electrode wear rate (EWR) in electric discharge machining (EDM) through a particular exploration of various parameters. These parameters included nano-powder concentration, electric current, and pulse-on time. By systematically analyzing and manipulating these variables, the study aimed to optimize the EDM process, thereby reducing energy consumption and enhancing the overall sustainability of the machining operation. We employed the Powder Mixed Electro-Discharge Machining (PMEDM) technique, a refined iteration of electric discharge machining. This innovative method blended graphite nano-powder with transformer oil to serve as the dielectric medium. The primary objective of this investigation is to examine the outcomes concerning crucial process parameters such as graphite powder concentration, electric current, and pulse-on time when machining high-speed steel, focusing mainly on electrode wear rate (EWR). Incorporating nano graphite (Gr) mixed powders into dielectric liquids has demonstrated a discernible enhancement in EWR across diverse operational conditions. The study found that the electrode wear rate (EWR) varied based on nano-powder concentration, electric current, and pulse-on time. Maximum EWR was observed at a concentration of 10 g/L, a current of 30 A, and a pulse-on time of 70 µs, while minimum EWR occurred at 0 g/L, 10 A, and 60 µs. The Full Factorial design, executed with MINITAB 17 software, validated these findings. The optimal EWR recorded was 1.154 mm3/min. The coefficient of determination (R-sq) for surface roughness prediction also stood at 91.15%.

Keywords
EDM, Nano-Powder Mixed Electro-Discharge Machining, Electrode Wear Rate, Full Factorial

Published online 7/15/2024, 8 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: Asaad A. ABBAS, Raed R. SHWAISH, Shukry H. AGHDEAB, Waleed AHMED, Energy efficiency and sustainability enhancement of electric discharge machines by incorporating nano-graphite, Materials Research Proceedings, Vol. 43, pp 124-131, 2024

DOI: https://doi.org/10.21741/9781644903216-17

The article was published as article 17 of the book Renewable Energy: Generation and Application

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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