Investigation of Machining Characteristics Using Different Types of Plant-Based Bio-dielectrics in Maglev EDM

Sustainable advanced manufacturing is an excellent alternative to the conventional approach to minimize (or) eliminate the hazardous effects of commonly used dielectrics in EDM. In the current research, the machining characteristics of Ti-6Al-4V alloy have been investigated using neem oil and canola oil as plant-based bio-dielectrics in Maglev EDM. The machining operation is conducted on a Ti-6Al-4V alloy workpiece (15 mm × 15 mm × 3 mm) using a cylindrical mild steel tool (ø = 3.3 mm). Material removal rate (MRR) and tool wear rate (TWR) have been evaluated for both bio-dielectrics. The results were compared for respective bio-dielectric at discharge voltage (22 V), discharge current (200 mA), and duty cycle (95%) for every experimental repetition. The voltage–current (V–I) waveforms analysis depicts stable and consistent pulses with minor irregularities. The obtained results show an MRR of 147.5 µg/min in the case of canola oil and 125.33 µg/min in the case of neem oil. Similarly, a TWR of 1.32 times higher was achieved using canola oil as compared to neem oil. The SEM micrographs and EDX reports help analyze the machined surface characteristics by observing the surface anomalies and material migration effect.