Supawi, Aiman (2023) Performance of RBD palm oil based dielectric fluid on sustainable electrical discharge machining (EDM) process of titanium alloys. Doctoral thesis, Universiti Tun Hussein Onn Malaysia.

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Abstract

In electrical discharge machining (EDM), the material removal is accomplished through a continuous discharge that occurs between the electrode and the workpiece in the presence of a dielectric fluid. Appropriate selection of dielectric medium is an important consideration due to the function of dielectric medium which greatly influences the performance of this process. Low machining efficiency and poor surface finish caused by using a conventional dielectric fluid that pollutes the environment and cause health problems in EDM processes have been issues that must be dealt well. The preliminary study aims to investigate the performance of biodegradable oil-based dielectric fluid compared to conventional dielectric fluid for titanium alloys (Ti-6Al-4V) with copper (Cu) electrode using a sustainable EDM. To achieve high EDM performance for this research, the main parameter of peak current (Ip); 6, 9 and 12A and pulse duration (ton); 50, 100 and 150μs were selected. Refine, bleach, and deodorized (RBD) palm oil, modified RBD palm oil, and kerosene were used as dielectrics. The influence on the machinabilities of the material removal rate (MRR), electrode wear rate (EWR), and sparking characteristic were experimentally investigated. Some aspects of surface integrity, such as surface roughness (Ra), recast layer (RL) and microhardness (MH) were also evaluated. The result shows that RBD palm oil has higher MRR, EWR, Ra and MH but lower RL compared to modified RBD palm oil and kerosene in term of machinability and surface integrity. This is due to the density, viscosity and flash point of the dielectric fluid that play a vital role in the determination of the desired outcome in the EDM process. The highest improvement of MRR is 567.43% when RBD palm oil is compared to kerosene at Ip=12A and ton=150μs. Overall, all dielectric fluids have almost similar trend. However, RBD palm oil based dielectric fluid is the best option for EDM machining of Ti-6Al-4V

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