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<p>Near Dry Electrical Discharge Machining (NDEDM) is a sustainable alternative to conventional EDM that uses a two-phase dielectric mist instead of hydrocarbon-based fluids. This study compares oxygen mist and EDM oil mist as dielectric media for machining Ti6Al4V, Inconel 718, and Hastelloy C276 using a ZNC-EDM machine. The influence of peak current (5–9&#xa0;A), pulse on-time (260–290&#xa0;µs), and mist concentration (5–15&#xa0;g/L) on Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) was analyzed using the Taguchi method and ANOVA. Results show that oxygen mist improved MRR by 23.5%, reaching a peak of 85.42&#xa0;mm<sup>3</sup>/min, while EDM oil reduced TWR by 18.7% and enhanced SR by 22.4%, achieving a minimum SR of 2.54&#xa0;µm. GA mist showed significantly lower tool wear (up to 12.7 × less than EDM oil) across all materials. Although EDM oil yielded lower SR numerically, GA mist provided better visual surface quality, especially for Ti6Al4V. ANOVA revealed that peak current was the dominant factor for MRR and TWR, while pulse on-time and off-time significantly affected SR. The optimal parameters for balanced machining were 7&#xa0;A, 275&#xa0;µs, and 10&#xa0;g/L mist concentration. This study provides performance-based guidance for selecting dielectric media in NDEDM. Oxygen mist is suitable for high material removal applications, while EDM oil mist is preferred for improved surface integrity and tool life.</p>

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A Comparative Investigation of Dielectrics for Near Dry EDM Process Optimization

  • 期刊论文

  • 发表日期：

    2025年5月23日

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  • Apurva Kulkarni,
  • Ganesh Dongre

摘要

Near Dry Electrical Discharge Machining (NDEDM) is a sustainable alternative to conventional EDM that uses a two-phase dielectric mist instead of hydrocarbon-based fluids. This study compares oxygen mist and EDM oil mist as dielectric media for machining Ti6Al4V, Inconel 718, and Hastelloy C276 using a ZNC-EDM machine. The influence of peak current (5–9 A), pulse on-time (260–290 µs), and mist concentration (5–15 g/L) on Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) was analyzed using the Taguchi method and ANOVA. Results show that oxygen mist improved MRR by 23.5%, reaching a peak of 85.42 mm3/min, while EDM oil reduced TWR by 18.7% and enhanced SR by 22.4%, achieving a minimum SR of 2.54 µm. GA mist showed significantly lower tool wear (up to 12.7 × less than EDM oil) across all materials. Although EDM oil yielded lower SR numerically, GA mist provided better visual surface quality, especially for Ti6Al4V. ANOVA revealed that peak current was the dominant factor for MRR and TWR, while pulse on-time and off-time significantly affected SR. The optimal parameters for balanced machining were 7 A, 275 µs, and 10 g/L mist concentration. This study provides performance-based guidance for selecting dielectric media in NDEDM. Oxygen mist is suitable for high material removal applications, while EDM oil mist is preferred for improved surface integrity and tool life.