Influence of workpiece materials on aerosol emission from die sinking electrical discharge machining process |
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| Affiliation: | 1. Department of Mechanical Engineering, National Institute of Technology, Tiruchirappalli, India;2. Department of Mechanical Engineering, College of Engineering, Kallooppara, Kerala, India;3. Cell for Industrial Safety and Risk Analysis, Central Leather Research Institute, Adyar, Chennai, India;4. Department of Electrical and Electronics Engineering, National Institute of Technology, Tiruchirappalli, India;1. Division of Minimally Invasive Gynaecological Surgery, St. Maria Hospital, University of Perugia, Terni, Italy;2. Division of Gynecologic Oncology, Department of Obstetrics and Gynecology, University of Insubria, Varese, Italy;3. Division of Gynecologic Oncology, Department of Obstetrics and Gynecology, Massachusetts General Hospital, Boston, Massachusetts;4. Department of Obstetrics and Gynaecology, Catholic University of the Sacred Heart, Rome, Italy;5. Division of Gynecologic Oncology, HIMA-San Pablo, Caguas, Puerto Rico;6. Division of Gynecologic Oncology, Cleveland Clinic, Cleveland, Ohio;7. The Kelly Gynecologic Oncology Service, Department of Gynecology and Obstetrics, Johns Hopkins Hospital, Baltimore, Maryland;8. Advanced Gynecological Endoscopy Center, Malzoni Medical Center, Avellino, Italy;1. Urology Unit Hospital Universitario San Ignacio Pontificia Universidad Javeriana, Bogotá, Colombia;2. Human Genetics Institute, Pontificia Universidad Javeriana, Bogotá, Colombia;3. Latin American Collaborative Study of Congenital Malformations, ECLAMC, Bogotá, Colombia;1. Faculty of Engineering and Applied Science, Memorial University of Newfoundland, St. John''s, NL, Canada A1B 3X5;2. Department of Civil and Environmental Engineering, Princeton University, Princeton, NJ 08544, United States;1. Università degli Studi dell’Insubria, Dipartimento di Scienza e Alta Tecnologia, via G.B. Vico, 46, 21100 Varese, Italy;2. Politecnico di Milano, Dipartimento di Chimica, Materiali e Ingegneria Chimica “G. Natta”, via Mancinelli, 7, 20131 Milano, Italy |
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| Abstract: | Simultaneous investigation of environmental emissions and machining aspects of electrical discharge machining process is essential for achieving hygienic and efficient machining. The main objective of the present work is to experimentally investigate and analyze the aerosol emission rate and the material removal rate from a die sinking electrical discharge machining process for three commonly used work piece materials viz., tool steel, mild steel and aluminum using Taguchi methodology of Experimental Design in order to suggest suitable process conditions for green manufacturing. The aerosol emission profile of all workpiece materials was found to be closely related to the material removal profile. A significant variation in emission and material removal rate was observed for workpiece materials which may be accorded to the variation in melting and vaporization temperatures. It was also observed that majority of aerosol constituents evolved from workpiece materials and that the constituents with low melting points were having high relative concentration in the aerosol emitted. The study introduced a parameter, the relative emission rate for comparing the emission for various process parameters and workpiece–tool material combinations. The favorable machining parameters for each material were then identified by employing signal to noise ratio analysis of the relative emission rate. |
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| Keywords: | Electrical discharge machining (EDM) Emission Aerosol Taguchi methodology Relative emission rate |
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