Effect of Dielectric Fluids on Surface Integrity in EDM

Republic of Iraq
Ministry of Higher Education and Scientific Research

University of Technology
Department of Production Engineering and Metallurgy
Study the effect of different dielectric fluid on

surface integrity for electrical discharge
machining (EDM)
A Thesis
Submitted to the Department of Production Engineering and
Metallurgy / University of Technology in a Partial Fulfillment of
the Requirements for the Degree of Master of Science in
Production Engineering
By
Haneen Lateef Abdulwahhab
Supervised by
Asst. Prof. Dr. Shukry Hammed Aghdeab
2019 A.D. 1440 A.H.

‫الرِحيم‬ ‫الر ْح ِِ‬
‫منِ َّ‬ ‫بِ ْسِمِ ِِ‬
‫اللهِ َّ‬
‫آمَ نواِإِذَاِقِ ي ِلَِلَكِ ِْمِتَفَ ِسَّحِ واِِِِِِ‬ ‫﴿ِيَاِأَيِ َهاِالَّ ِذ َِ‬

‫ينِ ِ‬
‫فِيِا ْلمَ ِجَ الِ ِِ‬

‫سِفَافْ ِسَ حِ واِيَفْسَِِحِاللَّهِِلَكِ ِْمِ َوإِذَا‬
‫يلَِانشِ زواِف انشِزواِيَ ْرفَِِعِاللَّهِِالَّ ِذي َِ‬

‫نِآمَنوا‬ ‫قِ ِ‬
‫ينِأوتواِا ْلعِْل ِمَِدَ َرجَاتِِ َواللَّهِِبِمَا‬

‫مِنك ِْمِ َوالَّ ِذ َِ‬
‫ونِخَبِيرِ(‪﴾ِ)۱۱‬‬
‫تَ ْعمَل َِ‬
‫الع ِظيم‬
‫قِاللهِ َ‬
‫صدَ َِ‬
‫س ورةالم ج ادل ة‬
Dedication
I dedicate this thesis
To my country
To lovely parents, my brother and close
friends
To all persons who have supported me and
encouraged me to complete this work

Acknowledgements
First of all, thanks to God for enabling me to complete this work.

Special thanks and deepest gratitude are dedicated to my supervisor Asst.
Prof. Dr. Shukry H. Aghdeab for his valuable guidance, advices, effort,
help and encouragement throughout this project. Great thanks to Asst.
Prof. Dr. Baha S. Mahdi Also, I would like to express my thanks to
Department of Production Engineering and Metallurgy and Training and
Workshops Center /Turning Unit at the University of Technology for their
cooperation and assistance. Finally, all thanks are extended to my father,
my mother, brother, cousins, and my close friends for their support and
encouragement. Special thanks go to those who supported, encouraged
and helped me.
Abstract
This thesis aims to investigate the effect of using different dielectric
liquids including transformer oil, gas oil, kerosene and vegetable oil
(sunflower) on the material removal rate (MRR), electrode wear ratio (EWR),
surface roughness (SR), white layer thickness (WLT), and micro-hardness
(HV) in EDM. Pulse-on-time of (50, 100, 200) µs and current of (10, 24, 50)
A have been chosen as input parameters. Machining was carried out on
stainless steel AISI 316L specimens with a copper electrode. The factorial
design was used to develop mathematical models for each dielectric fluid to
create plots to determine the (MRR, EWR, SR, WLT and HV) performance
with increasing pulse-on-time (Ton) and current(Ip). The results show that the
vegetable oil can be used as dielectric in EDM, it gives highest MRR, lower
EWR, best SR and high HV when compared to transformer oil, gas oil, and
kerosene. Analysis of variance results indicate that the pulse-on-time and
current are the most important factors. The MRR in vegetable oil, transformer
oil, gas oil produced 163%, 52%, and 5% higher MRR, respectively, than
kerosene and MRR increases with increase in Ton and IP. The EWR in
vegetable oil, kerosene, gas oil resulted in 48%, 30%, and 26% lower EWR
than transformer oil, EWR decreases with increase in Ton but increases with
increase in IP. The SR in vegetable oil, transformer oil, gas oil produced 47%,
27%, and 9% lower SR, respectively than kerosene. In addition, The WLT in
kerosene, gas oil and transformer oil resulted in approximately 62%, 28% and
14% lower WLT, respectively, compared to vegetable oil. The HV in
vegetable oil, transformer oil, and gas oil resulted in 11%, 2% and 0.5%
higher HV, respectively, than kerosene. The SR, WLT, and HV increases
with increasing Ton and IP.
A
Table of Contents
Subject Page
No.
Abstract A
List of Contents B
List of Figures H
List of Tables N
List of Abbreviations S
List of Symbols T
List of Contents
Subject Page
No.
Chapter one: principles of EDM
1.1 Introduction of EDM 1
1.2 Principles of EDM process 3
1.3 Mechanism of EDM Process 5
1.4 EDM process parameters 8
1.4.1 Input parameters 8
1.4.1.a Pulse on time (Ton) 8
1.4.1.b Pulse off time (Toff) 9
B
1.4.1.c Current 9
1.4.1.d Voltage 10
1.4.1.e Dielectric fluid 10
1.4.2 Response or performance parameters 11
1.4.2.a Material Removal Rate (MRR) 11
1.4.2.b Electrode wear (EW) 11
1.4.2.c Surface Roughness (SR) 13
1.4.2.d The surface layer 14
1.5 Properties of dielectric fluids that need to be considered while 15

selecting for operation
1.6 Functions of the Dielectric 16
1.7 Requirements of Dielectric Fluid 17
1.8 Advantages of EDM 17
1.9 Limitation of EDM 18
1.10 Applications of EDM 19
Chapter Two: Introduction and Literature Survey
2.1 Introduction 20
2.2 Summery of literature survey 32
2.3 Objective 35
Chapter Three: Experimental Work
3.1 Introduction 36
C
3.2 EDM Machine 36
3.3 The dielectric fluid 38
3.4 The workpiece material 38
3.5 The electrode tool material 41
3.6 Selection of the machining parameters 43
3.7 Experimental design 45
3.8 Experimental procedure 45
3.9 Measurement of responses 47
3.9.1 Measurement of material removal rate (MRR) and electrode 47

wear rate (EWR)
3.9.2 Measurement of surface roughness (SR) 48
3.9.3 Measurement of White Layer Thickness (WLT) 49
3.9.4 Measurements Micro hardness (HV) 52
Chapter Four: Results and discussion
4.1 Introduction 54
4.2 Design of experimental (DOE) 54
4.3 The Experimental Results 55
4.4 Dielectric transformer oil 64
4.4.1 Effect of pulse-on-time and current on MRR 64
D
4.4.2 Effect of pulse-on-time and current on EWR 65
4.4.3 Effect of pulse-on-time and current on SR 66
4.4.4 Effect of pulse-on-time and current on WLT 67
4.4.5 Effect of pulse-on-time and current on HV 68
4.5 Dielectric gas oil 69
4.6 Dielectric kerosene 73
4.7 Dielectric vegetable oil 78
E
4.8 The effect of different dielectric on MRR, EWR, SR, WLT and 83
HV
4.8.1 Analysis MRR for transformer oil, gas, kerosene and 85

vegetable oil
4.8.2 Analysis EWR for transformer oil, gas, kerosene and 86

vegetable oil
4.8.3 Analysis SR for transformer oil, gas, kerosene and vegetable 87

oil
4.8.4 Analysis WLT for transformer oil, gas, kerosene and vegetable 87
oil
4.8.5 Analysis HV for transformer oil, gas, kerosene and vegetable 89

oil
4.9 Models of Different dielectric 90
4.9.1.a. Analyzing factorial designs for MRR 90
4.9.1.b. Determining Degree of Regression Model for MRR 97
4.9.1.c. Model summary 98
4.9.2.a. Analyzing factorial designs for EWR 99
F
4.9.2.b. Determining Degree of Regression Model for EWR 106
4.9.3.a. Analyzing factorial designs for SR 108
4.9.3.b. Determining Degree of Regression Model for SR 115
4.9.4.a. Analyzing factorial designs for WLT 117
4.9.4.b. Determining Degree of Regression Model for WLT 124
4.9.5.a. Analyzing factorial designs for HV 126
4.9.5.b. Determining Degree of Regression Model for HV 133
Chapter five: Conclusion and recommendations for future work
5.1 Introduction 136
5.2 Conclusions 136
5.3 Recommendations for future work 138
References 139
G
List of Figures
Figure Figure name Page
No. No.
(1.1) Examples of Work Produced by EDM 1
(1.2) Die-Sinking EDM 3
(1.3) Electrical discharge machining (EDM)(a) general setup (b) 4

close-up view of gap, showing discharge and material
removal
(1.4) Electrical discharge machining 5
(1.5) EDM components 6
(1.6) EDM Spark Description 7
(1.7) Effect of Pulse On-Time on Crater size and Surface 9

Roughness
(1.8) Influence of Pulse Current on Crater size and Surface 10

Roughness
(1.9) Types of electrode wear in EDM 12
(1.10) (a) The influence of current on surface finish (or crater size) 13
(b) The influence of frequency of sparking on surface finish
(or crater size)
(1.11) Surface finish is function of discharge current and 13

frequency of discharge
(1.12) Layers formed by EDM Process 14
H
(3.1) CHEMER EDM machine 37
(3.2) The workpiece before machining 40
(3.3) The copper electrode before machining 41
(3.4) The EDM machine screen 43
(3.5) The digital balance instrument 48
(3.6) Surface roughness device 48
(3.7) The sample after mounting 49
(3.8) The grinding machine 50
(3.9) The polishing machine 50
(3.10) The etching process 51
(3.11) Optical-microscope 52
(3.12) White layer thickness 52
(3.13) The Digital micro-hardness 53
(4.1) The effect of Ton and Ip on MRR at constant Toff (25 µs) for 64
transformer oil.
(4.2) The effect of Ton and Ip on EWR at constant Toff (25 µs) for 65
transformer oil.
(4.3) The effect of Ton and Ip on SR at constant Toff (25 µs) for 66
transformer oil.
(4.4) The effect of Ton and Ip on WLT at constant Toff (25 µs) for 67
transformer oil.
I
(4.5) The effect of Ton and Ip on HV at constant Toff (25 µs) for 68
transformer oil.
gas oil
gas oil
gas oil
gas oil
gas oil
kerosene
kerosene
kerosene
kerosene
kerosene
vegetable oil.
vegetable oil.
J
vegetable oil.
vegetable oil.
vegetable oil.
(4.21) Material removal rate comparison between transformer oil, 85

gasoil, kerosene and vegetable oil
(4.22) Electrode wear rate comparison between transformer oil, 86

gas oil, kerosene and vegetable oil
(4.23) Surface roughness comparison between transformer oil, gas 87

oil, kerosene and vegetable oil
(4.24) White layer thickness comparison between transformer oil, 88

(4.25) Micro-hardness comparison between transformer oil, gas 89

oil, kerosene and vegetable oil
(4.26) The normal probability plots of residuals for MRR for: (a) 93
Transformer oil (b) gas oil (c) kerosene, and (d) vegetable
oil
(4.27) Comparison of experimented and predicted MRR values for 94

transformer oil

gas oil

kerosene
K
vegetable oil
(4.31) The normal probability plots of residuals for EWR for 102
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d)
vegetable oil
(4.32) Comparison of experimented and predicted EWR values for 103

transformer oil

gas oil

kerosene

vegetable oil
(4.36) The normal probability plots of residuals for SR for 111

vegetable oil.
(4.37) Comparison of experimented and predicted SR values for 112

transformer oil

gas oil

kerosene

kerosene
L
(4.41) The normal probability plots of residuals for WLT for 120
vegetable oil.
(4.42) Comparison of experimented and predicted WLT values for 121

transformer oil

kerosene

gas

vegetable oil
(4.46) The normal probability plots of residuals for HV for 129

vegetable oil
(4.47) Comparison of experimented and predicted HV values for 130

transformer oil

kerosene

gas

vegetable oil
M
List of Tables
Table Table name Page
No.
No.
(2.1) Summary of Literature Survey 32-35
(3.1) CHEMER EDM machine specification 37
(3.2) Specification of power supply 37
(3.3) The physical properties of the vegetable oil, transformer oil, 38

(3.4) The chemical composition of workpiece material 39
(3.5) The chemical composition of workpiece material (AISI 40

316L)
(3.6) The physical properties of workpiece material (AISI 316L) 40
(3.7) The mechanical properties of 316L stainless steel 41
(3.8) Chemical composition of copper electrode 42
(3.9) Physical properties of the copper electrode 42
(3.10) Mechanical properties of the copper electrode 43
(3.11) The machining parameters 45
(4.1) Experimental results for MRR, EWR, SR, WLT and HV 56

with transformer oil
N
(4.2) The experiments results 57

with gas.

with kerosene

with vegetable oil
(4.8) The experiments results. 63
(4.9) Values of experimented and predicted MRR for 91

transformer oil
(4.10) Values of experimented and predicted MRR for gas oil 91
(4.11) Values of experimented and predicted MRR for kerosene 92
(4.12) Values of experimented and predicted MRR for vegetable 92

oil
(4.13) ANOVA table for MRR for transformer oil 96
(4.14) ANOVA table for MRR for gas oil 96
(4.15) ANOVA table for MRR for kerosene 97
(4.16) ANOVA table for MRR for vegetable oil 97
(4.17) Model summary for MRR for transformer oil 99
O
(4.18) Model summary for MRR for gas oil 99
(4.19) Model summary for MRR for kerosene 99
(4.20) Model summary for MRR for vegetable oil 99
(4.21) Values of experimented and predicted EWR for 100

transformer oil
(4.22) Values of experimented and predicted EWR for gas oil 100
(4.23) Values of experimented and predicted EWR for kerosene 101
(4.24) Values of experimented and predicted EWR for vegetable 101

oil
(4.25) ANOVA table for EWR for transformer oil 105
(4.26) ANOVA table for EWR for gas oil 105
(4.27) ANOVA table for EWR for kerosene 106
(4.28) ANOVA table for EWR for vegetable oil 106
(4.29) Model summary for EWR for transformer oil 107
(4.30) Model summary for EWR for gas oil 108
(4.31) Model summary for EWR for kerosene 108
(4.32) Model summary for EWR for vegetable oil 108
(4.33) Values of experimented and predicted SR for transformer 109

oil
(4.34) Values of experimented and predicted SR for gas oil 109
P
(4.35) Values of experimented and predicted SR for kerosene 110
(4.36) Values of experimented and predicted SR for vegetable oil 110
(4.37) ANOVA table for SR for transformer oil 114
(4.38) ANOVA table for SR for gas oil 114
(4.39) ANOVA table for SR for kerosene 115
(4.40) ANOVA table for SR for vegetable oil 115
(4.41) Model summary for SR for transformer oil 116
(4.42) Model summary for SR for gas oil 117
(4.43) Model summary for SR for kerosene 117
(4.44) Model summary for SR for vegetable oil 117
(4.45) Values of experimented and predicted WLT for 118

transformer oil
(4.46) Values of experimented and predicted WLT for gas oil 118
(4.47) Values of experimented and predicted WLT for kerosene 119
(4.48) Values of experimented and predicted WLT for vegetable 119

oil
(4.49) ANOVA table for WLT for transformer oil 123
(4.50) ANOVA table for WLT for gas oil 123
(4.51) ANOVA table for WLT for kerosene 124
(4.52) ANOVA table for WLT for vegetable oil 124
Q
(4.53) Model summary for WLT for transformer oil 125
(4.54) Model summary for WLT for gas oil 126
(4.55) Model summary for WLT for kerosene 126
(4.56) Model summary for WLT for vegetable oil 126
(4.57) Values of experimented and predicted HV for transformer 127

oil
(4.58) Values of experimented and predicted HV for gas oil 127
(4.59) Values of experimented and predicted HV for kerosene 128
(4.60) Values of experimented and predicted HV for vegetable oil 128
(4.61) ANOVA table for HV for transformer oil 132
(4.62) ANOVA table for HV for gas oil 132
(4.63) ANOVA table for HV for kerosene 133
(4.64) ANOVA table for HV for vegetable oil 133
(4.65) Model summary for HV for transformer oil 137
(4.66) Model summary for HV for gas oil 137
(4.67) Model summary for HV for kerosene 137
(4.68) Model summary for HV for vegetable oil 137
R
List of Abbreviations
Abbreviation Description Unit
EDM Electrical Discharge Machining ---
WEDM Wire Electrical Discharge Machining ---
DC Direct Current A
Ebm Weight of electrode before machining g
Eam Weight of electrode after machining g
MRR Material Removal Rate mm³/min
EWR Electrode Wear Ratio %
SR Surface Roughness µm
WLT Whit Layer Thickness µm
HV Micro-Hardness kg/mm2
HAZ Heat Affected Zone ---
EDG Electrical discharge grinding ---
CAD Computer Aided Design ---
CNC Computer Numerical Control ---
Wbm Weight of the workpiece before machining g
Wam Weight of the workpiece after machining g
S
TWR Tool wear rate g/min or
mm3/min
NAS North American stainless ---
AISI American Iron and Steel Institute
PMD powder-mixed-dielectric ---
GPMKD graphite powder mixed kerosene dielectric ---
KD Kerosene dielectric ---
BD1 Vegetable oil 1 ---
BD2 Vegetable oil 2 ---
DOE Design of experimental L9
List of Symbols
Symbol Description Unit
NaCl sodium chloride ---
Br Brass ---
Cu Copper ---
TiC Titanium carbide ---
TiO Titanium oxide ---
Ip Current A
T
NC Numerical Control ---
Al /SiC Aluminum/ Silicon carbide ---
R-sq The determination coefficient ---
R-Sq Adjusted determination coefficient ---

(adj)
SE Coef Standard Error of the Coefficient ---
SEM Scanning Electron Microscope ---
Adj SS Adjusted Sums of Squares ---
ANOVA Analysis Of Variance ---
R-Sq Predicted determination coefficient ---

(pred.)
Adj MS Adjusted Mean Squares ---
S Standard deviation ---
Ton Pulse on time µs
Toff Pulse off time µs
T Machining time min
V Voltage V
WC-Co Tungsten cobalt ---
W/O Water in oil ---
U
 Density g/mm3
P Applied load N
D impression diagonals mm
MMCS Metal matrix composite ---
HSS High speed steel ---
B4C Boron carbide ---
AISI American Iron and steel Institute ---
C2H2O2 Chemical solution oxalic acid ---
DF Degree of Freedom ---
KHZ Kilohertz KHZ
WC Tungsten carbide ---
W/m.k Watt/meter. kelvin
SVO Servo Feed %
W.T Working Time sec.
JD jumping distance mm
H.V High Voltage V
V
Chapter one Principle of EDM
1.1 Introduction of EDM
Electrical discharge machining (EDM), is an important non-traditional

manufacturing method, developed in the late 1940s, has been accepted
worldwide as a standard process in the manufacture forming tools used to
produce plastics mouldings, die casting, forging dies etc.
EDM technology is increasingly being used in tool, die and mould making
industries, for machining heat treated tool steels and advanced materials (super
alloys, ceramics and metal matrix composites) requiring high precision,
complex shapes and high surface finish. Traditional machining technique is
often based on the material removal using tool material harder than work
material. Heat treated tool steel has proved to be extremely difficult-to-machine
using traditional processes, due to rapid tool wear, low machining rates,
inability to generate complex shapes and imparting better surface finish [1]. Fig.
(1.1) illustrates examples of work produced by EDM.
Fig. (1.1) Examples of Work Produced by EDM [2].
New developments in the field of material science have led to new engineering
metallic materials, composite materials and high technology ceramics, with
-1-
good mechanical properties and thermal characteristics as well as sufficient

electrical conductivity so that they can be readily machined by spark erosion.
The recent developments in the field of EDM have progressed due to the
growing application of EDM process and the challenges faced by the modern
manufacturing industries, from the development of new materials that are hard
and difficult-to-machine such as tool steels, composites, ceramics, super alloys,
carbides, stainless steels, heat resistant steel, etc. Being widely used in die and
mould making industries, aerospace, and aeronautics. Many of these materials
also find applications in other industries owing to their high strength to weight
ratio, hardness and heat resisting qualities. EDM has also made its presence felt
in new fields such as sports, medical and surgical instruments, optical, dental
and jewellery industries, including automotive R&D (Research and
development) areas [1, 2].
The EDM process involves two phases, rough machining and finish
machining. Rough machining phase requires high machining efficiency with a
certain surface quality, while the finish- machining phase requires high surface
quality. In rough machining phase, the material is removed at a faster rate
irrespective of the surface quality [3]. Due to the faster material removal from
the workpiece, the material debris gathers in the narrow discharge gap which
leads to abnormal discharges like “arcing”. Arcing is a series of discharge that
strike repeatedly on the same spot [4]. There are several types of machines and
industrial applications that employ the EDM process for high precision
machining of metals. The two primary types of EDM systems are "Die-Sinking"
and "Wire" EDM. Die-Sinking machines are also called Sinker, Ram-Type,
Conventional, Plunge or Vertical EDM. Die-sinking type EDM machines
require the electrode to be machined in the exact opposite shape as the one in
-2-
the workpiece see Fig. (1.2). Die-sinking EDM machines use hydrocarbon oil
in which the workpiece is submersed and will be subjected to sparking upon
power discharge [5-6].
Fig. (1.2) Die-Sinking EDM [5, 6].
1.2 Principle of EDM process
In EDM process, the material is removed from the workpiece due to

erosion cause by rapidly recurring spark discharge between the tool and
workpiece. The workpiece and tool are separated by a thin gab about (0.01-0.5)
mm. Both workpiece and tool are submerged in a dielectric fluid. Kerosene, oil,
deionized water is very common type of liquid dielectric although gaseous
dielectric can also be used in certain case. The workpiece works as the anode
and the tool as the cathode, which are linked to a power supply with pulsed
direct current (DC) [8]. An EDM setup is shown in Fig. (1.3) [9]. The final form
of the workpiece surface is produced by means of a formed electrode tool as
shown in Fig. (1.3-a). EDM process includes controlled erosion of electrically
conductive materials by the initiation of rapid and frequent electrical discharge
-3-
between the workpiece and tool [10], which generates a track for each discharge
where the liquid becomes ionized in the gap, as shown in Fig.(1.3-b).
Fig. (1.3) Electrical discharge machining (EDM) (a) general setup (b) close-up
view of gap, showing discharge and material removal [9].
The moment spark leads to sufficient pressure which develops between

workpiece and tool as a result of which a very high temperature is reached at.
Because of this high pressure and temperature, some part of metal is melted and
eroded. Such localized extreme rise in temperature leads to material removal.
Material removal occurs due to instant vaporization of the material as well as
due to melting. The flowing dielectric liquid flushes the small debris particles
far away from the gap [9]. It is to keep the appropriate gap between the
workpiece and tool to create the spark discharge. The gap can be changed to
suit the machining conditions like material removal rate. If the electrode tool is
fed downwards, maintaining the predetermined gap, the tool shape/profile will
be reproduced on the workpiece. When the voltage gradient set up between the
workpiece and the tool is sufficient for breakdown the dielectric liquid, a
conducting electrical track is developed for spark discharge causing ionization
of the fluid and leading to a current flow. The temperature of the location hit by
-4-
the spark may rise up to 10000 ºC causing to melt and vaporize the workpiece
and finally to take the shape of sphere before quenched by the fluid medium.
Higher gap despite it increases the energy of discharge, but it decreases
frequency of spark. This is due to an increase in the charging time of the
capacitor. A servo-control unit is used to sense a previous gap voltage compare
it with a used value in order to keep a previously identified gap. The difference
in voltage is used for setting the gap by controlling the servomotor movement,
as shown in Fig. (1.4) [10].
Fig.(1.4) Electrical discharge machining [10].
1.3 Mechanism of EDM Process
Electrical discharge machining, or spark machining, as it is also called,

removes material with repetitive spark discharges from a pulsating DC power
supply, with a dielectric flowing between the workpiece and the tool. The tool
is mounted on the chuck attached to the machine spindle whose motion is
controlled by a servo-controlled feed drive. The workpiece is placed in a tank
-5-
filled with a dielectric fluid; a depth of at least (50mm) over the work surface is
maintained to eliminate the risk of fire. The tool and workpiece are connected
to a pulsating power supply. Dielectric fluid is circulated under pressure by
pump, as shown in Fig. (1.5) [11]. The mechanism of material erosion basically
uses the electrical energy and converts it into thermal energy by a series of
intermittent electrical discharges that occur between the workpiece and
electrode tool submerged in a dielectric liquid. The thermal energy creates a
plasma channel between the anode and cathode [12, 13].
Fig.(1.5) EDM components [11].
EDM input power is first converted into continuous DC power by conventional

solid-state rectifiers. The flow of this DC power is then controlled by a bank of
power transistors which are switched by a digital multi vibrator oscillator
circuit. The high-power pulsed output is then applied to the workpiece and tool
to get the sparks responsible for removing the material [11]. A direct current of
low voltage and high amperage is delivered to the electrode at the rate of
-6-
approximately 20 - 30 (KHZ) [14, 15]. The erosion of the spark of the work
material makes the use of electrical energy, converted into thermal energy
through a series of repetitive electrical discharges between the tool electrode
and the work material electrode. The thermal energy creates a plasma channel
between the two electrodes, at a temperature ranging from (8000 - 12,000) °C,
and high up to 20,000 °C. This heat causes some portion of the surrounding
dielectric fluid to evaporate; it additionally melts and vaporizes the metal to
form a small hole on the work surface as shown in Fig.(1.6)[16]. Since the spark
always occurs between the tool points and the workpiece closest together, the
high points of the workpiece are gradually eroded. Where the dielectric liquid
expels the condensed metal globules formed during the process by the flow of
the dielectric liquid. In the EDM cycle, each pulse lasts for only a few
microseconds. Pulses are repeated at rates up to 100,000 per second. These
repeated pulses lead to erosion of material from the workpiece and from the
electrode. When the process is progresses, the electrode is advanced toward the
workpiece by the servo-drive to maintain a constant gap until the completion of
the final cavity [11, 15].
Fig.(1.6) EDM Spark Description [16].
-7-
1.4 EDM process parameters
For the advancement of manufacturing method or to work economic

machining one must classify the method and efficiency checking the
parameters. The parameters of EDM process can be ordered into:
1.4.1 Input parameters

The input parameters of EDM process which affects the performance of
machining, operation are discharge current, polarity, pulse off time (Toff), pulse
on time (Ton), voltage, dielectric fluid, gap voltage, servo feed rate (SVO),
diameter of electrode, working time (WT) and jumping time (JT). The process
parameters are chosen accordingly for ideal machining condition [17].
1.4.1.a Pulse on time (Ton)
This represents the time period during which the pulse is on, it is measured
in microsecond (µs). The material removed increases when the sparking time
(pulse on time) is increased. A result, the craters will be deeper and broader.
Therefore the surface finish is rougher. While producing a better surface finish
when the shorter duration of sparks. The spark leaves the tool and hits the
workpiece which are positively charged thus producing the machining effect.
While in roughing operation, all the sparks that leave the tool result in a
microscopic removal of particles of the surface. Much more wear because of
more sparks, therefore, this operation behaves quite inverse to normal operation
in which the tool wears more during finishing than roughing [18]. Fig. (1.7)
demonstrates the effect of pulse duration on crater size increase with the
consequential increase of metal removal rate and surface roughness [19].
-8-
Fig.(1.7) Effect of Pulse On-Time on Crater size and Surface Roughness [19].
1.4.1.b Pulse off time (Toff)
It is measured in microsecond (µs) and defined as the time period

between every two successive electrical sparks, the off time during which the
pulse rests and re-ionization takes place in the dielectric fluid. This parameter
can affect the stability and speed of operation. If the (Toff) is very short, this will
make sparks be unstable, thus slowing down the cycle of operation [20].
1.4.1.c Current (Ip)
It is one of the most important machining parameters in EDM process. It can be

defined as a measure of the amount of the electrical charges flowing between
the tool electrode and workpiece. The unit used to measure the electric current
is ampere (A). Increasing the current will improve material removal rate but has
a negative effect on the tool wear and surface finish, thus the material removal
rate is directly proportional to the current. Fig. (1.8) shows the influence of
current on the crater size and hence the removal rate and surface roughness [19,
21].
-9-
Fig.(1.8) Influence of Pulse Current on Crater size and Surface Roughness

[19].
1.4.1.d Voltage
The voltage usually used is a DC power source of 40 to 400Volts. An AC

power source can also be used, but it is usually coupled with a DC rectifier. The
preset voltage determines the width of the spark gap between the leading edge
of the electrode and the workpiece. High voltage settings increase the gap and
hence the flushing and machining[22].
1.4.1.e Dielectric fluid

The material removal rate (MRR) mainly occurs due to thermal evaporation
and melting. Thermal process is done without oxygen so the process can be
controlled and oxidation can be avoided. Oxidation causes poor surface
conductivity (electrical) of the workpiece which hinders further machining. The
dielectric fluid gives an oxygen free machining environment. It should have
high electrical resistance, so that it does not breakdown electrically easily and
also thermal resistance during sparking. The dielectric liquid generally used are
EDM oil, kerosene and deionized water. It is also applied through the tool to
achieve efficient removal of molten material [8].
- 10 -
1.4.2 Response or performance parameters

These parameters are used for the evaluation of machining process in both
qualitative and quantitative terms. Some of the response characteristics are
material removal rate (MRR), electrode wear rate (EWR), surface roughness
(SR), white layer thickness (WLT) and micro-hardness (HV) [17].
1.4.2.a Material Removal Rate (MRR)
The material is removed from both the tool and the workpiece, the (MRR)
depends on the workpiece material, as well as on the material of electrode and
the variable cutting. For example, electrode polarity, pulse conditions, and the
machining medium. In such manner, a material of low melting point has high
material removal rate, and for this reason has high surface roughness. Typical
(MRR) is from (0.1- 400) mm³/min [23].
Wbm−Wam
MRR = ……….. (1.1)
t×ρ
Where:
MRR = material removal rate (mm3/min).
Wbm = Weight of workpiece before operation (g).
Wam = Weight of workpiece after operation (g).
t = Machining time (min).
ρ = Density of workpiece material (g/mm3).
1.4.2.b Electrode wear (EW)
In EDM, Electrode wear is one of the most affecting factors. The change in
electrode shape by electrical sparks, electrode wear ratio can be defined as the
ratio of the amount of machining of the workpiece to the amount of electrode
- 11 -
wear. EWR changes depend on the combination of electrode material and

workpiece material, pulse on time, current, pulse off time, polarity, voltage and
other process parameters [24]. Also, it relies upon the flow of dielectric liquid
in the cutting gap, increase electrode wear when the liquid flow is very turbulent
[25]. The point of melting is considered a factor of great significance in
determining an electrode wear. Fig. (1.9) shows the ratios of electrode are the
end wear, side wear, corner wear and the volume wear.
Fig.(1.9) Types of electrode wear in EDM [26].
Ebm −Eam
EWR = × 100% …….. (1.2)
Ebm
Where:
EWR = electrode wear ratio (%).
Ebm = Weight of electrode before operation (g).
Eam = Weight of electrode after operation (g).
- 12 -
1.4.2.c Surface Roughness (SR)

It is the surface produced by electrical discharge machining (EDM)
process consisting of a large number of craters formed by the discharge energy.
The factors effecting surface roughness are current and frequency. Increasing
the current leads to increase in material removal rate (MRR) and surface
roughness (SR), as shown in Fig.(1.10-a). As for frequency, increasing in
frequency of the spark will improve the surface quality by reducing the (SR)
and gives a softest surface, as shown in Fig. (1.10-b) [28]. The best surface
finish is produce in EDM by operating at low discharge currents and high
frequencies, as shown in Fig. (1.11) [10].
Fig.(1.10) (a) The influence of current on surface finish (or crater size) (b) The
influence of frequency of sparking on surface finish (or crater size) [28].
Fig. (1.11) Surface finish is function of discharge current and frequency of

discharge [10].
- 13 -
1.4.2.d The surface layer
To check of part of the surface layer produced by EDM, Fig.(1.12) shows

that there is a top white layer, which crystallizes from the liquid cooled at high
speed. The depth of this top melted zone depends on the pulse energy and
duration. Below the top layer is a chemically affected layer with changes in the
average chemical composition and possible phase changes. The EDM process
changes not only the surface of the work metal, but also the subsurface. Three
layers are created on the top of the unaffected work metal. The spattered EDM
surface layer is created when the expelled molten metal and small amounts of
electrode material form spheres and spatter the surface of the work metal. This
spattered material is easily removed. The following layer is the recast (white)
layer the action of EDMing has actually altered the work metal's metallurgical
structure and characteristics in the recast layer. This layer is formed by the
expelled molten metal solidifying in the crater. The molten metal is rapidly
quenched by the dielectric. The last layer is the heat affected zone or annealed
layer, which has only been heated, not melted. The depth of the recast layer and
the heat affected zone is determined by the heat sinking ability of the material
and the power used for the cut. This altered metal zone influences the quality of
the surface integrity [29].
Fig. (1-12) Layers formed by EDM Process [29].

- 14 -
1.5 Properties of dielectric fluids that need to be considered while

selecting for operation [9].
Dielectric resistance: The a ability of the fluid to maintain high resistivity

before spark discharge and in turn the ability to recover rapidly with a minimal
amount of OFF time. Oil with a high dielectric strength will offer a finer degree
of control throughout the range of frequencies used.
Viscosity: The viscosity of the fluid is one of the most influential factors on
accuracy and finishes. In mirror finishing or close tolerance operations,
spark gaps can be as small as 0.5 or less.
Color: All dielectric oils will eventually darken with use, but it seems only
logical to start with a liquid that is as clear as possible to allow viewing of the
submerged part. Clear or “water-white” should be your choice, because any
fluid that is not clear when brand new certainly contains undesirable or
dangerous contaminants.
Odour: The oils that have a strong odour give an indication for the presence of
sulfur which is undesirable in the EDM process.
Polarity: In EDM, polarity describes which side of the spark gap is

positive or negative. Polarity can effect speed, finish, wear, and machining
stability. Spark erosion machines can use both positive and negative polarity,
depending upon the particular application, but most operations are performed
using a positive electrode.
Polarity will remove material more slowly than negative polarity, but it is used
most of the time to protect the electrode from excessive wear. Negative polarity
is used for high speed metal removal when using graphite electrodes, and should
- 15 -
be used when machining carbides, titanium, and refractory metals using

copper electrodes. Negative electrodes polarity is sometimes used with
copper electrodes when no other method is as successful. With graphite
electrodes, negative polarity is much faster than positive polarity by as much as
50% or more, but with as much as (30- 40) % electrode wear.
1.6 Functions of the Dielectric [8].

Insulation: One important function of the dielectric is to insulate the workpiece
from the electrode. The disruptive discharge must take place across a spark gap
which is as narrow as possible. In this way efficiency and accuracy are
improved.
Ionization: As quickly as possible optimum conditions for the production of an
electrical field must be created and then a spark path must be provided. After
the impulse the spark path must be deionized quickly so that the next discharge
can be made. The dielectric ought to constrict the spark path as much as
possible, so that high energy density is achieved, which increases discharge
efficiency at the same time.
Cooling: The spark has a temperature of 8000 – 12000 °C when it punctures

the workpiece and so the dielectric must cool both the electrode and the
workpiece. Overheating of the electrode must be avoided, so that excessively
high electrode wear cannot occur. It must be possible for the metal gases which
develop during spark erosion to condense in the liquid.
Removal of waste particles: Metal particles that have been eroded away must
be removed from the area of erosion by the dielectric to avoid disruptions in the
process.
- 16 -
1.7 Requirements of Dielectric Fluid [8]

1- The dielectric fluid should have sufficient Stable dielectric strength to
provide insulation between the tool and workpiece till the break down voltage
is reached.
2- It should have a good wetting capacity to provide effective cooling

mechanism.
3- It should flush out the particles produced during the spark out of the gap. This
is the most important function of dielectric fluid. Inadequate flushing can result
in decreasing the life of the electrode and increasing the machining time.
4- It should be chemically neutral so as not to react with the electrode, the
workpiece, the table or the tank.
5- The flash point should be high so that there are no fire hazards.
6- Neither emission of any toxic vapours nor unpleasant odours are desirable.
7- It should maintain these properties with temperature variation, contamination
by working residuals and products of decomposition.
8- It should be economical and easily available.
1.8 Advantages of EDM [30]

EDM has the following advantages:
1. Cutting any electrically conductive material by the EDM process.

2. It can produce the intricate molds and dies with a highly accuracy, cheap cost
and faster.
3. The high degree of automation, three axes motion make programming of
intricate shapes by using the simple electrodes.
4. Holes of desired size can be easily made in hard and brittle materials.
- 17 -
5. There is no direct contact between tool and workpiece. Therefore delicate

sections and weak materials can be machined without any distortion.The cutting
tool should not be harder than the workpiece, because there is no mechanical
contact between them.
6. Carbide tools, dies and intricate forms can be made economically.
7. Machining time is less than traditional machining processes.
1.9 Limitation of EDM
(a) The need for electrical conductivity-the workpiece has to be electrically

conductive to be able to create discharges. Isolators like plastics, glass and most
ceramics cannot be machined by EDM, although some exception like for
example diamond is known. Machining of partial conductors like Si
semiconductors, partially conductive ceramics and even glass is also possible.
b) Predictability of the gap-The dimensions of the gap are not always easily
predictable, especially with complex workpiece geometry.
(c) Low material removal rate-The material removal of the EDM process is
low, especially in the case of die-sinking EDM where the total volume of a
cavity has to be removed by melting and evaporating the metal. With wire EDM
only the outline of the desired workpiece shape has to be machined. Due to the
low material removal rate, EDM is principally limited to the production of small
series although some specific mass production applications are known.
(d) Optimization of the electrical parameters-The choice of the electrical
parameters of the EDM process depends largely on the material combination of
electrode and workpiece and EDM manufactures only supply these parameters
for a limited amount of material combinations. When machining special alloys,
the user has to develop his own technology.
- 18 -
(e) Heat Affected Zone (HAZ) near cutting edges.

(f) Dielectric vapour can be dangerous.
1.10 Applications of EDM [31]

EDM has the following applications:
1. The EDM process is a common method of making prototype and production
parts, especially in the aerospace, automobile and electronics industries in
which production quantities are relatively low.
2. It is used to machine extremely hard materials that are difficult to machine

like alloys, tool steels, tungsten carbides etc.
3. It is used for drilling of curved holes.
4. It is used for internal thread cutting and helical gear cutting.
5. It is used for machining sharp edges and corners that cannot be machined
effectively by other machining processes.
6. In EDM machining higher Tolerance limits can be obtained. Hence areas that
require higher surface accuracy use the EDM machining process.
8. It is a promising technique to meet increasing demands for smaller

components usually highly complicated, multi-functional parts used in the field
of micro-electronics.
- 19 -
Chapter Two Introduction and literature survey
2.1 Introduction
This chapter gives a review of literature in the fields related to Electrical

Discharge Machining (EDM), especially on dielectric and its effect on
machining characteristic such as material removal rate (MRR), electrode wear
ratio (EWR), surface roughness (SR), white layer thickness (WLT), micro-
hardness (HV). The literature available on EDM at dielectric change liquids are
given below.
A.Erden and D.Temel (1982) [32] investigations conducted on

electric discharge machining (EDM) where water has been used as dielectric
liquid instead of usual kerosene, tap water, Distilled water, and Distilled water
with sodium chloride (NaCl) and glycerine additives are used as dielectric
liquids in the experiments. The results show that the machining performance of
distilled water with salt additive is found to be very poor. Poor machining
performance due to the presence of ions in the water and to considerable
oxidation. Tap water also results in oxidation and excessive short circuits.
Similarly Distilled water with glycerin result instability and excessive short
circuits. The best machining performance is achieved with distilled water, and
it is found that the eroded craters obtained in distilled water and kerosene are
usually smaller in volume (both diameter and depth wise), but machining rates
are increased due to improved stability during continuous machining and
shorter time lags for dielectric breakdown.
Kunieda M. et al. (1997) [33] in this paper, show that gas can be used
as dielectric in electric discharge machining (EDM) process, and comparison of
machining performance in air with those for EDM in liquid. The workpiece and
the electrode were made of steel and copper respectively. It was found that in
- 20 -
the case of EDM in air, the tool electrode wear ratio is much lower and the
material removal rate is much higher when the polarity of the tool electrode is
negative compared with the case in which the polarity of the tool electrode is
positive. In contrast, in the case of EDM in a liquid, there is less tool electrode
wear and higher material removal rate when the polarity of the tool electrode is
positive. The results in air show that the EWR is almost zero for any pulse-on-
time, with increasing the concentration of oxygen in air, the MRR is improved
due to heat generation caused by oxidation of the electrode materials.
Chen et al. (1999) [34] studied and analyzed the machining

characteristics of Titanium alloy employing different dielectrics, distilled water
and Kerosene are used as dielectric liquids for comparison. The results show
that the MRR of titanium alloy is greater while the EWR is lower when using
distilled water rather than Kerosene. This is due to the formation of Titanium
carbide (TiC) and Titanium oxide (TiO) on the workpiece surface when using
kerosene and distilled water, respectively. When machining Titanium alloy by
using kerosene, lower MRR was observed. This can be explained by both the
formation of TiC which has a higher melting temperature. Therefore it requires
a greater discharge energy, and carbon deposition on this tool, causing further
retardation of the discharge process. A larger amount of debris and extra micro
cracks of Titanium alloy are also found when using distilled water as the
dielectric
Fábio N. Leão and Ian R. Pashby (2004) [35] studied the

importance of the dielectric fluid, which affects factors such as productivity and
quality. Health, safety and environment are also important factors. Hydrocarbon
- 21 -
oils are more efficient than deionized /distilled water in die sink applications.
However, water may result in higher levels of material removal rate in some
situations. Authors have studied the feasibility of adding organic compounds to
deionized water and obtained a performance higher than that of hydrocarbon
oils for roughing and finishing operations. Increase in material removal rates up
to 100% in roughing operations has been reported Water-based dielectrics can
replace hydrocarbon oils as they have higher performance and are more
environmentally suitable.
Biing Hwa Yan et al. (2005) [36] evaluated the machining

performance of EDM and the feasibility of modifying the surface by adding
urea into the dielectric used in machining pure titanium metal In the
experiments, machining parameters such as the dielectric type (distilled water
or distilled water+ urea), peak current values(0.5, 1.7, 3,5, 8, 10, 12)A and pulse
duration values (25, 50, 100, 150, 200, 300)μs were changed to explore their
effects on machining performance, including the material removal rate,
electrode wear rate and surface roughness. The results show that when adding
urea into the dielectric, MRR and EWR increased with an increase in peak
current. Moreover MRR and EWR declined as the pulse duration increased.
This was due to the peak current increase, increasing the discharge energy.
Additionally, the surface roughness deteriorated with an increase in peak
current. Since an increase in the peak current increased the discharge energy
and the impulsive force, removing more molten material and generating deeper
and larger. Discharge craters. Hence, the surface roughness became coarser.
- 22 -
C. J. Luis et al. (2005) [37] studied the material removal rate (MRR)
and electrode wear (EW) on the die-sinking electrical discharge machining
(EDM) of siliconised has been carried out. This study was made only for the
final stages and has been carried out on the influence of five design factors:
intensity supplied by the generator of the EDM machine (3, 4, 5), pulse time
(30, 50, 70) μs, open-circuit voltage (-120, -160, -200) V and dielectric flushing
pressure (20, 40, 60) Kpa, over the two previously mentioned response
variables. In the research a mineral oil is used as dielectric fluid for the EDM
machine with a flash point of 82℃. The electrodes used were made of
electrolytic copper (with a cross-section of 12mm×8 mm). In the case of MRR,
the only influential design factors, for a confidence level of 95%, were: intensity
and voltage. The EWR tends to decrease with flushing pressure of dielectric is
increased.
B Ekmekci. Et al (2005) [38] studied the influence of electrode

material and type of dielectric liquid on the surface integrity of plastic mold
steel samples is investigated. The results have shown that regardless of the tool
electrode and the dielectric liquid, the white layer is formed on machined
surfaces. This layer is composed of cementite (Fe3C) and martensite distributed
in retained austenite matrix form dendritic structures, due to rapid solidification
of the molten metal, if carbon-based dielectric liquid is used. The intensity of
cracking increases at high pulse durations and low pulse currents. Cracks on the
EDM surfaces have been found to follow the pitting arrangements with closed
loops and to cross perpendicularly with radial cracks and continue to propagate
when another discharge takes place in the neighborhood. The amount of
retained austenite phase and the intensity of micro-cracks have found to be
- 23 -
much less in the white layer of the samples machined in deionized water
dielectric liquid.
F. Shehata. et al. (2006) [39] presented the machining characteristics

of Al/SiC MMCS (metal matrix composite) were investigated with kerosene
and paraffin oil as the dielectrics. The working fluid plays an important role
affecting the metal removal rate, Tool wear rate and the properties of machined
surface. The results show that the metal removal rate has greatly increased by
increasing discharge current, and it is found that the tool wear is lower and better
surface roughness are found when using kerosene as a dielectric fluid, while the
metal removal rate is lower than that in the case of paraffin oil. When kerosene
is used, a black carbide layer is formed on the workpiece surface (AL4C3) has a
higher melting temperature (2100℃) while discontinuous white calcium deposit
is formed on the workpiece surface Ca (880 ℃) when using paraffin oil.
Ravindra K. et al. (2007) [40] emphasized at the development of

optimization models to correlate the various machining parameters such as peak
current values (6, 9, 12) A, pulse on time values (5, 7, 11) μs and pulse off time
(3, 6, 9)μs on material removal rate (MRR) and tool wear rate (TWR) of high
speed steel with copper and brass electrode for Electrical Discharge machining
(EDM) process. The machining parameter include pulse-on-time, pulse-off-
time, peak current and fluid pressure. In this research oil is used as dielectric
fluid and the side injection of dielectric fluid with side jet flushing system was
employed to assure adequate flushing of the EDM process debris from the gap
zone during experiment cylindrical solid rod of copper and brass with 6µm
diameter is used as tool electrode and the work piece of high speed steel is
- 24 -
machined for 20 minutes to record the readings the obtained results evidence
that as the material removal rate is increased with increase in pulse-off-time and
peak current. Material removal rates decreased with increase in pulse on time
in case of brass electrode and decrease in cooper electrode, and it is found that
the Copper is found to be having the highest MRR as compare to Brass. The
EWR of Brass is very high and Copper has less EWR
G. Kibria. et al. (2010) [41] this study has been performed for
micro-electrical discharge machining of titanium alloy to investigate the
influence of different dielectrics such as kerosene, deionized water, boron
carbide (B4C) powder suspended kerosene, and deionized water on machining
performance characteristics such as material removal rate (MRR), tool wear rate
(TWR). The result show that the MRR and TWR are higher using deionized
water than kerosene. Also, when boron carbide-mixed dielectrics are used,
MRR is found to increase with deionized water, but TWR decreases with
kerosene dielectric, and it's found that the thickness of white layer is less on
machined surface when deionized water is used as compared to kerosene. It can
be concluded from the research investigation that there is a great influence of
mixing of boron carbide additive in deionized water dielectrics for enhancing
machining performance characteristics in micro-EDM during micro-hole
generation on Titanium alloy.
Animesh Prakesh and Governdra singh (2012) [42] this paper

reviews the electric discharge machining of high speed steel by using only
kerosene and gas with kerosene as dielectric medium for study the influence of
material removal rate and tool wear ratio. Work piece was taken as a square
block of Hight speed steel (HSS) material having size of 1.5cm and the tool
- 25 -
electrode was made up of a copper pipe with thin wall having thickness of
0.5mm.The controllable parameter are discharge current, pulse on time, and gap
voltage. The researchers work with two cases. In the first case they perform
when only kerosene was used as dielectric as medium. In the second case both
are used as dielectric medium. The result was different when executed by only
kerosene and when executed by both. When compressed air was used at that
time the material removal rate was increased and the tool wear ratio was
decrease. The same is trail for gap voltage parameter which is the most
important parameter when both liquid are used as a dielectric as compared to
discharge current and discharge current is was most important parameter when
only kerosene was used as dielectric.
Minh Dang Nguyen et al. (2012) [43] this study aims to suppress
the electrochemical reaction in die-sinking using deionized water by employing
short voltage pulse. Deionized water has been used as dielectric fluid because it
gives higher material removal rate and lower tool wear than hydrocarbon oil.
Moreover, it is a relatively low-cost and eco-friendly substance. Therefore,
deionized water tends to be more favorable for EDM. However, it causes weak
electrochemical reaction during EDM Due to its slight conductivity. The results
show that the electrochemical reaction in micro-EDM using deionized water
can be reduced by using short voltage Pulse. Pulse-on time is the main factor
that affects the electrochemical reaction rate. And it's found that the MRR of
deionized water was more than 20 times higher than MRR of EDM oil. Also,
when deionized water was used as dielectric fluid, the debris formation was
found to be less because there was no carbon decomposed from dielectric fluid.
- 26 -
Yanzhen Zhange et al. (2012) [44] presents a comparative study on

the performance of three types of dielectrics at different electrical discharge
machining (EDM) parameter combinations favorable for generating porosity.
Beside the dielectrics type, the influence of the EDM parameters, such as peak
current values (9, 15) A and pulsed duration values (150, 308) μs. The properties
of the porosity formation in the recast layer formed in water/ oil emulsions
(W/O) were investigated by comparing them with those present in the recast
layer formed in kerosene and deionized water dielectric. When machining was
performed in (W/O) emulsion, the quantity of both the external and internal
pores in the recast layer was larger than the case of kerosene and deionized
water. Generally speaking, the machined surface was worse when machining
was performed in the (W/O) emulsion. The results showed that the density of
the pores increased with the increasing pulse duration regardless of the
dielectric types.
Yonghong Liu et al. (2014) [45] a systematical and comprehensive

investigation of the material removal properties of the electrical discharge
machining (EDM) operation using five dielectric air, oxygen, deionized water,
kerosene and water-in-oil (W/O) and five different pulse duration values (52,
105, 210, 420, 840) μs. The results show that the volume of melted material was
the largest in (W/O) emulsion dielectrics. In oxygen, the volume of melted
material was a little larger than that in air. In kerosene, the volume of melted
material was much smaller than in other dielectrics. The results show that the
removal efficiency shows a great difference in different dielectrics and is pulse
duration dependent. Generally speaking, the removal efficiency was higher in
- 27 -
liquid dielectrics than that in gaseous dielectrics; higher at short pulse duration
than that at long pulse duration.
Xiangzhi Wang et al. (2014) [46] describes the influence of

dielectric characteristics, namely, electrical conductivity, oxidability and
viscosity on the electrical discharge machining (EDM) of titanium alloy. The
experimental materials included distilled water, tap water, tap water with 30 %
hydrogen peroxide (H2O2) solution, and kerosene. The experimental parameters
employed based on experience included voltage of 250V, current of 8A, pulse
on time of 80 μs, and pulse off time of 85 μs. Comparative experiments on
titanium alloy EDM in compound dielectric, distilled water, and kerosene were
performed to analyze the difference in material removal rate (MRR), relative
electrode wear ratio (REWR), and surface roughness (SR). The results show
that the MRR of titanium alloy in the compound dielectric was the highest,
approximately 1.5 times of that in distilled water and five times of that in
kerosene. The REWR in the compound dielectric was 27%lower than that in
kerosene, whereas the SR was approximately 14 % lower than that in distilled
water. The new compound dielectric solves the problems of low MRR in
kerosene and poor surface quality in distilled water of titanium alloy machined
by EDM.
S. Chakraborty et al. (2015) [47] presented a review on the use of

different kinds of alternative dielectric fluid and their effect for EDM
characteristic. It examined using kerosene, water tap, distilled water and
hydrocarbon oils as dielectric with copper electrode. The results show that the
distilled water as a dielectric has higher MRR and less electrode wear (EW)
- 28 -
than hydrocarbon oils when a high pulse energy range was used. With distilled
water, the machining accuracy is poor but the surface finish is better. Work
piece surface roughness is also dependent on the type of dielectric fluid. Surface
roughness produced with deionized water is generally lower than that with
hydrocarbon oils. Electric discharge machining can also be achieved with
gaseous dielectrics such as air and oxygen. It is found that gaseous dielectric
can provide higher material removal rates than that with hydrocarbon oil.
Sanghani C. R. et al. (2016) [48] reviewed the study work carried

out to evaluate the effect of different dielectric fluid on performance measures
such as material removal rate (MRR), tool wear rate (TWR),and surface
roughness of electrical discharge machining using different dielectric fluids like
kerosene, deionized water, air, mineral oil, powder mixed dielectric, etc. The
results show that the water is dielectric in EDM achieving zero electrode wear
in special condition. In case of distilled water, surface finish/ integrity is
generally poorer than that of hydrocarbon oils as higher concentration of micro
cracks and voids are formal as well. Authors have investigated the feasibility of
dry EDM for 3D surface machining and found excellent profile accuracy and
less tool electrode wear ratio compared to oil EDM. Most of the research work
was done using air and oxygen as dielectric fluid for improvement of MRR.
Sarosh M.J et al. (2016) [49] intended to investigate the impact of

process parameter such as discharge current values (3, 6, 9)I, pulse on time
values(60, 90, 120) μs, and pulse off time values(3, 4, 5) μs. The three levels
were employed to minimize the surface roughness. Other parameters such as
Servo speed, polarity and dielectric pressure wear kept constant throughout the
- 29 -
machining. A copper electrode tool was used to machine the holes in tool steel
workpiece with kerosene oil as dielectric. The results show that the surface
roughness increase when discharge current and pulse on time is increased while
non-significant effect was found in terms increase pulse off and gap.
Janak B. Valaki and Pravin P. Rathod. (2017) [50] in this

article, have proposed two vegetable oil-based biodielectric fluids: Jatropha oil
(BD1) and WVA (BD2), as green dielectrics for EDM process. Experimental
investigation was carried out to evaluate the relative performance of the
proposed biodielectric fluid with kerosene to analyze m work material removal
rate (MRR), electrode wear rate (EWR), and relative wear ratio (RWR) for tool
steel using electrolytic grade copper electrode. Influence of control parameter
such as current values (3, 6, 9, 12, 15, 18)A, gap voltage values(30, 40, 50, 60,
70, 80)KV, pulse on time values(21, 50, 100, 200, 400, 600)μs, and pulse off
time values(6, 11, 20, 30, 40, 75) μs have been chosen as input parameters. The
results show that the Vegetable oil-based biodielectrics BD1 and BD2 is higher
MRR for die sinking EDM than kerosene as dielectric. It was found that the
EWR with BD1 and BD2 biodielectrics was higher than kerosene. BD1 and
BD2 exhibited response patterns were similar to kerosene for MRR, EWR, and
RWR. This indicates that material process mechanics and erosion phenomenon
for biodielectrics are similar to kerosene. This proves the feasibility of
biodielectrics for EDM. BD2 is found to be the best fluid for MRR and RWR
followed by BD1 and kerosene.
Misbah Niamat et al. (2017) [51] kerosene and distilled water

dielectrics were evaluated for Aluminum alloy due to its wide applications in
- 30 -
aerospace and automotive sector. The effects of parameters such as current (6,
9, 11)A and pulse-on-time(15, 30, 45) μs on material removal rate (mm3/min),
electrode wear rate (mm3/min), and microstructures were evaluated and
comparisons were made for the accomplishment of dielectrics (kerosene and
distilled water).The results show that the material removal rate increase with
the increase of pulse-on-time and current, Higher pulse-on-time exhibited
lower EWR, however, reverse effect has been observer with higher values of
current. Kerosene as dielectric has higher MRR and lower electrode wear rate
than distilled water. It was found that the Rougher surface can be obtained with
distilled water dielectric in comparison with kerosene as illustrated by
micrographs.
Sadagapan P. and mauliprasanth B. (2017) [52] investigated

the effect of using different dielectrics, biodiesel, transformer oil and kerosene
on the material removal rate, electrode wear and surface roughness in EDM.
Based on Taguchi’s design of experiments, machining were carried out on
Aluminum Alloy specimens using a die-sinking EDM machine fitted with a
copper electrode. The results show that the biodiesel as a dielectric in EDM
gives high MRR, less EWR and better surface finish when compared to the
widely used kerosene and transformer oil. It was also found that the material
removal rate (MRR) is mainly affected by peak current (Ip) followed by the
pulse-on-time (Ton).moreover the effect of Pulse-off-time (Toff) is negligible,
As well biodiesel and transformer oil emanate lesser smoke and fewer odours.
- 31 -
2.2 Summery of Literature Survey

From literature review, it is observed that these researches focuses on the
influences of different dielectric fluid such as (kerosene, distilled water, tap
water, water in oil, and vegetable oil (Jatropha, WAV) on MRR, EWR, and
microstructure. Some of literature reviewed studied the influences of machining
parameters like (Ton , Toff , IP) on MRR and EWR. The literature survey can be
summarized according to its references in the following Table:
Table (2.1) Summary of Literature Survey.
Ref. Dielectric Conclusion

32 kerosene, tap water, Distilled The best machining performance
water, and Distilled water with is achieved with distilled water.
sodium chloride (NaCl) and
glycerine
33 Gas, air and oil with steel alloy The MRR is improved and EWR
is almost zero when using air as
dielectric
34 Kerosene and distilled water The MRR is greater, the relative

with titanium alloy. electrode wear ratio is lower and
more micro cracks, when
machining in distilled water rather
than kerosene.
- 32 -
35 hydrocarbon oil and deionized Water-based dielectrics can

/distilled water replace hydrocarbon oils as they
have higher performance and are
more environmentally suitable.
36 adding urea into the distilled When adding urea into the
water as dielectric used in dielectric, MRR, EWR, and SR
machining pure titanium increased with an increase in peak
current. Moreover MRR and
EWR declined as the pulse
duration increased.
38 Influences of different type of It was found that if carbon-based
dielectric liquid on surface dielectric liquid is used. The
integrity intensity of cracking increases at
high pulse durations and low pulse
currents
39 Kerosene and paraffin oil Lower MRR and EWR, while the
SR is better than that when
machining in kerosene rather than
paraffin oil.
37,40,49 The effect of different (pulse- The result show that the (MRR,
on-time and current) on the EWR and SR) increase with
performance machining by increase current but the effect of
using different dielectric the pulse-on-time varies from one
research to another.
- 33 -
41 Kerosene, deionized water, The experimental results revealed

boron carbide (B4C) powder that MRR, TWR are higher and
suspended kerosene, and WLT is less when deionized water
deionized water is used than kerosene. Also, when
boron carbide-mixed dielectrics
are used, MRR is found to
increase with deionized water, but
TWR decrease with kerosene
dielectric.
42 Kerosene, and gas with When used gas with kerosene as
kerosene as dielectric used in dielectric the MRR was increased
machining high speed steel. and the TWR was decrease.
43 Deionized water, hydrocarbon Deionized water gives higher
oil MRR, lower EWR and less debris
formation than hydrocarbon oil.
Moreover, it is a relatively low-
cost and eco-friendly substance.
44 Water-in-oil(W/O), kerosene, The machined surface was worse

deionized water when machining was performed in
the W/O emulsion.
45 Gaseous dielectrics (air and The MRR was higher in liquid
oxygen) Liquid dielectrics dielectrics than that in gaseous
(deionized water, kerosene and dielectrics
water-in-oil (W/O)).
- 34 -
46 Compound dielectric, distilled The new compound dielectric

water and kerosene in solves the problems of low MRR
machining pure titanium. in kerosene and poor surface
quality in distilled water.
47 Kerosene, water tap, distilled The best machining rates (higher
water and hydrocarbon oils. MRR, lower EWR, and lower SR)
have been achieved in water rather
than hydrocarbon oils.
50 Vegetable oil 1 (BD1), BD1 and BD2 resulted higher
vegetable oil 2 (BD2), and MRR and EWR respectively, than
kerosene kerosene.
51 Kerosene and distilled water Kerosene showed higher MRR,
with aluminum alloy lower EWR, and lower SR than
distilled water.
52 Biodiesel, transformer oil and Biodiesel it gives high MRR, less
Kerosene EWR and better SF when than
kerosene and transformer oil.
2.3 Objective
The aim of this thesis is to study the effect of different dielectric fluid on surface
integrity such as (MRR, EWR, SR, WLT, HV) in electrical discharge machining
(EDM) of AISI 316L stainless steel workpiece with copper electrode and find
the best dielectric fluid of transformer oil, gas oil, kerosene, and vegetable oil
(sunflower) under different pulse-on-time and current values. MRR, EWR, SR,
WLT, and HV predication will be studied using full factorial design.
- 35 -
Chapter Three Experimental Work
3.1 Introduction
This chapter deals with the practical experimentation and selection of

machining variables of (EDM). It includes the specifications of machine,
dielectric solution, workpiece, electrode material characterization and
measurement of the Material Removal Rate (MRR), Electrode Wear Ratio
(EWR), Surface Roughness (SR), White Layer Thickness (WLT) and Micro
hardness (HV).
3.2 EDM Machine
In this study, the practical experiments was accomplished on a die sinking

EDM machine called CHMER of model (CM 323C) at the training and
workshop center at the University of Technology, as shown in Fig. (3.1). This
machine was designed by advanced CAD system to ensure deformation free
performance. The polarity of the electrode was set as positive while that of
workpiece is negative. This machine has many components such as tank for the
dielectric fluid, pump to recycle the dielectric fluid, the rectangular table for
mounting the workpiece, filters to clean the dielectric fluid and tool holder to
fix the electrode above the workpiece while leaving as small gab between them.
EDM machine specification is shown in table (3.1). The power was supplied to
the machine used in this experiment, specification of power supply is shown in
table (3.2) [53].
- 36 -
Fig. (3.1) CHEMER EDM machine at U.O.T.
Table (3.1) CHEMER EDM machine specification [53].

Table size (W×D) 500×350 mm
Work tank size (W×D×H) 820×500×300 mm
Table travel (X,Y) 300×200 mm
Ram travel (Z) 300 mm
Max. electrode weight 60 kg
Table (3.2) specification of power supply [53].

Model 50N Unit
Max. machining current 50 A
Max. power input 5 kVA
Electrode wear rate 0.2 %
Best surface roughness(Ra) 0.25 µm
Outside dimensions 620×850×1860 µm
Weight 180/396 kg/lb
- 37 -
3.3 The dielectric fluid
The dielectric fluid plays a very important role in the EDM process such
as productivity (MRR, EWR, and WLT), cost and quality (SR) of the machined
parts. In addition to health, safety and environment aspects are also to be
considered. In this experimental, an attempt is made to machine stainless steel
316L using transformer oil, gas oil, kerosene, vegetable oil (sunflower), Tap
water and water cooling car as dielectric. Vegetable oil contain free fatty acids
contents less than 1% and traces of other impurities are less than 1%. The
physical properties of the transformer oil, gas oil, kerosene and vegetable oil as
dielectrics are listed in table (3.3).
Table (3.3) The physical properties of the vegetable oil, transformer oil, gas oil,
kerosene and vegetable oil.
Dielectric Density Viscosity Boiling Specific Flash
(g/cm3)at (pa.s) at point heat point
15 oC 40 oC temp(oC) (KJ=kg.K) temp(oC)
Transformer 0.850 16.5 280 1.63 140

oil
Gas oil 0.850 5.6 200 2.05 60
Kerosene 0.801 2.71 150 2.01 40
Vegetable oil 0.916 28.7 300 2.17 158
3.4 The workpiece material
In this work it important to consider high hardness in selecting material. So

it has been used stainless steel AISI 316L. The sheet was imported from the
company of Maintenance Metals and Alloys Inc located in USA. The sheet has
- 38 -
dimensions (500 x 200) mm and uniform thickness (2mm). The sheet was cut
into small pieces with dimensions (40 x 30) mm by wire EDM machine, the
shape of workpiece is shown in Fig. (3.2). The stainless steel AISI 316L is
austenitic alloy. The chemical composition for stainless steel 316L are shown
in table (3.4). These alloys contain chromium, nickel and molybdenum, the last
which improved tensile strength, resistance to pitting makes it more corrosion
resistant and rupture resistance in the high temperature. They have higher creep
resistance, excellent formability and non-magnetic alloys. Corrosion resistance
is improved, particularly against hydrochloric, sulfuric, acetic, formic acids;
acid sulfates and alkaline chlorides [54]. The sample was examined in North
American stainless (NAS) Company Results of the analysis of the chemical
composition, physical properties and mechanical properties were calculated
according to the international specifications, as shown in the Tables (3.5), (3.6)
and (3.7).
Table (3.4) The chemical composition of workpiece material (AISI316L)[54].

Composition Type 316L %
Carbon 0.03 max.
Manganese 2.00 max.
Phosphorous 0.045 max.
Sulfur 0.030 max.
Silicon 0.75 max.
Chromium 16.00 – 18.00
Nickel 10.00 – 14.00
Molybdenum 2.00 – 3.00
Nitrogen 0.1 max.
Iron Balance
- 39 -
40 mm
2 mm
Fig. (3.2) The workpiece before machining.

Table (3.5) The chemical composition of workpiece material (AISI 316L).
Metals C% Cr% Cu% Mn% Mo%
Results 0.0137 16.5675 0.3935 1.2375 2.1170
Metals N% Ni% P% S% Si%
Result 0.0494 10.0450 0.0290 0.0010 0.2400
Table (3.6) The physical properties of workpiece material (AISI 316L).
Elastic Density Thermal Specific Specific
Grade Modulus (g/cm³) Melting point Conductivity Electrical thermal

(GPa) (W/m.°C) Resistivity capacity
(Ωmm²/m) (J/kg.°C)
316L 200 7.99 (1375-1400)°C 51 0.75 500
- 40 -
Table (3.7) The mechanical properties of 316L stainless steel.

Grade Tensile Elongation Yield strength Hardness
Strength(Mpa) (%) (Mpa) HRB
316L 560 49.09 290 84
3.5 The electrode tool material
The most important considerations when selecting EDM electrodes are high
corrosion resistance, good material conductivity and high melting point which
give the tool a longer life. EDM electrodes include components made from
brass, copper and copper alloys, graphite, molybdenum, silver and tungsten.
Copper and copper alloys have better EDM wear resistance than others. It is a
plate with dimensional (90×40×9mm), as shown in Fig. (3.3) before machining.
Tables (3.8), (3.9) and (3.10) show the chemical composition, physical
properties and mechanical properties of the copper electrode, which was
examined in the central organization for standardization and quality control/
Baghdad Iraq.
90 mm
40 mm
9 mm
Fig. (3.3) The copper electrode before machining.
- 41 -
Table (3.8) Chemical composition of copper electrode.
Metals Results Metals Result

Zn% 0.0001 Al% 0.0024
Pb% 0.0005 S% 0.0001
Sn% 0.0005 As% 0.0001
P% 0.0001 Ag% 0.0024
Mn% 0.0002 Co% 0.0004
Fe% 0.0091 Bi% 0.0001
Ni% 0.0004 Cd% 0.0001
Si% 0.0373 Sb% 0.0017
Cr% 0.0008 Cu% Residual
Table (3.9) Physical properties of the copper electrode.
Physical properties Values

Electrical conductivity (S/m) 58.5
Thermal Conductivity at 20 °C (W/m.°C) 18
Electrical resistivity at 20 °C (Ωmm²/m) 0.017
Modulus of elasticity (Gpa) 115
Thermal expansion coefficient (ppm/°C) 17.7
Melting point (°C) 1083
Density (g/cm³) 8.94
- 42 -
Table (3.10).Mechanical properties of the copper electrode.
Mechanical Properties Description

Tensile Strength (MPa) 620
Elongation (%) 7
Yield strength (MPa) 579
Hardness, HRB 62
3.6 Selection of the machining parameters

The parameters used in this experiment depend on the available parameter
in EDM CHMER machine. The EDM parameters as shown in Fig. (3.4).
Fig. (3.4) The EDM machine screen.
These parameters of the EDM machine are:-
1. S code: function S code list, S code number from (0-9). The S code (026)
has been selected.
- 43 -
2. Pulse-on-time (Ton): used to adjust pulse-on-time, pulse on adjusting is

from (1-24) step. (1) is the code for the shortest pulse-on-time and (24) is
the code for the longest pulse-on-time. And the values of (Ton) selected
are: 50, 100, and 200 (µs).
3. Pulse-off-time (Toff): used to set pulse-off-time, pulse off setting has a (1-
24) step. The values of (Toff) selected are: 25 (µs).
4. High voltage (H.V): based on the high voltage mode. We can increase
working stability and speed but will widen the cavity and electrode wear.
The value that has been selected is (240 V).
5. Current: A proper setting based on "current" factor is selected to adjust
the discharging speed. The values selected of current are: 10, 24, and 50
(Ampere).
6. Gap voltage: used to set the gap discharge voltage. The gap value is (1)
to (16) step, the smaller value is the narrower the gap will be. Generally
gap voltage is between (50 V) and (100 V). The gap value selected is (10)
equivalent to (0.3125 mm).
7. Servo feed (SVO): To adjust feed rate of an axis to help improve
discharge stability. There are (16) steps. The value that has been selected
is (100 %).
8. Working time (WT): it is used to set the range of working time from (0.1)
to (10) second and divided into (40) steps. The selected value is (0.6 S).
9. Jumping time (JT): it is used to set the jumping time and backward
distance. Jumping distance is from step (1) to step (120). The value
(2mm) has been chosen.
- 44 -
3.7 Experimental design
The experimental design is very important to calculate the number of

experiments needed. It involves two parameters and three levels. Parameter
with selected levels are shown in table (3.11). Nine experimental runs were
performed individually for transformer oil, gas oil, kerosene and vegetable oil.
Effect of parameters pulse-on-time and current on materials removal rate
(MRR), electrode wear ratio (EWR), surface roughness (SR), white layer
thickness (WLT), and micro hardness (HV) was determined for each dielectrics
separately. Furthermore, comparison of each dielectrics (transformer oil, gas
oil, kerosene and vegetable oil) was performed against MRR, EWR, SR, WLT,
and HV.
Table (3.11). The machining parameters.

Machining Levels
No parameters Symbol Unit Level 1 Level 2 Level 3
1 Pulse-on- Ton µs 50 100 200
time
2 Current Ip A 10 24 50
3.8 Experimental procedure
The machine used for this experiments is a die sinking EDM machine called
CHMER, model (CM 323C). The EDM process is performed on stainless steel
AISI 316L workpiece which is made anode. The electrode material used is
copper tool which is cathode and also using transformer oil, gas oil, kerosene
and vegetable oil as dielectrics. The steps are as following:
- 45 -
1. Preparation of the workpiece: the workpiece sheet has dimensions (500 x

200) mm and uniform thickness (2mm). Cutting the sheet into small pieces with
dimensions (40 x 30) mm by wire EDM machine.
2. Preparation of electrode: the plate of copper has dimensions (90×40×9 mm).

The electrode end is polished using fine emery sheet before every experiment.
4. Cleaning the workpiece and electrode from the contaminants before their
weight.
5. Using the digital balance to measure the initial and final weight of the
workpiece and electrode before and after machining.
6. The electrode was put in the tool holder that makes it cathode terminal and
be sure the balance of the electrode by indicator gauge.
7. The sample was put in the workpiece holder to be fixed and makes it anode
terminal.
8. When using transformer oil must be close the dielectric fluid tank and switch
on the pump for recycling the fluid to the level at which the tool and workpiece
submerge completely.
9. When using the vegetable oil, gas and kerosene as dielectrics. In this case the
dielectric is placed in the plastic basin and used submersible motor pump for
raising and recycling the fluid to the level at which the tool and workpiece
submerge completely.
10. Setting the desired machining parameters for each experiment using the
machine window and control panel.
11. All the specimens are cut (1mm) from one side by EDM machine, where
the dimensions become (39×30×2mm).
- 46 -
12. After the end of each experiment, the sample and electrode were cleaned
from the dielectric remains. Then their weights were measured to determine the
MRR and EWR for each experiment.
13. The data were collected and recorded from the machine window and the
digital balance.
3.9 Measurement of parameters
3.9.1 Measurement of material removal rate (MRR) and

electrode wear ratio (EWR)
The weight of the workpiece and electrode before and after machining was
measured with the help of an electronic weighing balance (Denver Instrument).
It is electrical instrument and it has a high precision equivalent to (0.001) g. The
measuring range is from (0.1 mg) to (210 g), the balance device is shown in Fig.
(3.5). Materials removal rate (MRR) is calculated according to the equation
(1.1) in chapter one, which depends on the weight of the workpiece before and
after machining, and also on the calculated machining time. Electrode wear ratio
is an important factor because it affects dimensional accuracy and the shape
produced. The electrode wear ratio is expressed as the difference of weight of
the electrode before and after the machining to the weight of the electrode
before machining, which is multiplied by 100% as mentioned in equation (1.2)
in chapter one.
- 47 -
Fig. (3.5) The digital balance instrument.
3.9.2 Measurement of surface roughness (SR)

In this work, the surface roughness (SR) measurement was taken at three
different regions on the machined surface. The mean of these three
measurements was taken as the final value for the surface roughness and
measured in µm. A profilo-meter made by Maher Federal Company, type
Pocket surf PS1 was used to measure SR. The probe scans the surface, compare
between peaks and valleys to indicate the SR. The probe movement during the
trace was digitally displayed, as shown in Fig. (3.6).
Fig. (3.6) Surface roughness device.
- 48 -
3.9.3 Measurement of White Layer Thickness (WLT)
Samples were prepared to show the microscopic of the samples according to

many steps done at metal preparation and metal testing laboratories in the
Production Engineering and Metallurgy Department/University of Technology
as follows:
1- Cutting
Cutting process was done by electric saw, cut all specimens into small
pieces with desired dimensions (1 x 1) mm and constant thickness (2mm)
from the same side that was cut in EDM machine.
2- Mounting
The mounting process is done after cutting specimens into small pieces.
The samples must be mounted by a mixture of self-curing dental base acrylic
resin as a powder with special liquid then mixing them very fast and pouring
them on the sample. The mixture is left on the sample for several minutes
until it become hard and dry, as shown in Fig (3.7)
Fig. (3.7) The sample after mounting.
- 49 -
3- Grinding
Grinding process was done by a disk rotary instrument with water using
emery paper (sic) paper with varying degrees of smoothness starting from
220,320,500,800,1000, and ending in 1200, respectively. The grinding
machine (DAP-5) works at voltage (220 V) and current (3 A) is shown in
Fig. (3.8).
Fig. (3.8) The grinding machine.
4- Polishing
The polishing was done on polishing cloth with a slurry of alumina

(Al2O3) until they become like mirror. The polishing machine (Metaserv)
works at voltage (230 V-240 V) and current (2.85 A) is shown in Fig. (3.9).
Fig. (3.9) The polishing machine.
- 50 -
5- Etching
The etching is a process that describes the crystalline border using

chemical solution oxalic acid ( C2H2O2) with distilled water and DC power
supply obtained for the purpose of showing the microscopic structure of
austenitic stainless steel AISI 316L. The samples were first immersed in the
solution and adjust the current values of (50 A) at the voltage (90 V) was
applied to the specimen at a period (45-55) seconds shown in Fig (3.10), then
washed with tap water and finally dried by an air dryer.
Fig. (3.10) The etching process.
6- Microstructure examination
The microstructure evolution was examined for samples to measure

the thickness of white layer by means of a metallographic microscope
utilizing microscope (Kruss) connected to the computer, samples were seen
under the magnifying instrument and the photomicrographs were taken as
shown in Fig. (3.11) and (3.12).
- 51 -
Fig. (3.11) Optical-microscope. Fig. (3.12) White layer thickness
3.9.4 Measurements Micro hardness (HV)
Vickers micro hardness tester was used to measure the hardness of

the samples, the load value of (9.807N, 1Kg) for (15) secojnd. Three
readings were recorded for each sample and average of them was taken.
As in Fig. (3.13), The Vickers hardness method is easier than any other
method, because the required calculations are not related to measuring
the size of the head of the device, and no need to change it regardless of
the hardness of the material to be measured. This test can determine the
hardness of the hard metals due to the use of the diamond pyramid and
the loads are very small when compared with the loads in the Brinl
hardness test and can be determined by this test to determine the hardness
of metals and micro-the Digital micro-hardness tester used is in
Production Engineering and Metallurgy department/University of
Technology. The average value of micro hardness was obtained by using
the formula as follows [55]:-
- 52 -
HV = 1.8544 × (P/d²) ....... (3.1)

Where:
P = applied load (kg).
d = impression diagonals (mm).
Fig. (3.13) The Digital micro-hardness.
- 53 -
Chapter Four Results and Discussion
4.1 Introduction
This chapter presents an analysis of the relative performance of the
proposed dielectrics, such as, transformer oil, gas oil, kerosene, and vegetable
oil. Influence of using different control parameters (pulse-on-time and current)
on the output for 36 samples made of stainless steel AISI 316L as a workpiece
with uniform thickness using copper as electrode. Factorial was used to develop
a mathematical model to predict the various response properties by using the
Minitab 18 software then analysis the predicted results and compare them with
experimental values.
4.2 Design of experimental (DOE)
The experimental (DOE) design was used to create factorial design of

the experiments under machining for two factors and three levels. The data entry
was done through the screen. Factorial is a set of statistical and mathematical
techniques useful for analyzing and modeling of data in which response
influenced by many variables and the target is to find the relationship between
the response and the variables. Factorial was applied using Minitab 18 software
that is one of the most important computer programs used in the statistical
analysis. The factorial includes designing a series of experiments for optimizing
the response and developing a mathematical model to predict the response of
EDM process with the best fitting. It is an empirical modeling technique used
to predict the response and find the effect of different process variables of input
factors and their interactions and well-fitted factors for dielectrics were chosen
for the experiment. Regression analysis was conducted to see the difference
between the main effects of levels 1, 2 and 3 of the variables on the MRR, EWR,
SR, WLT and HV.
- 54 -
4.3 The Experimental Results
Design of experimental (DOE) having nine experimental runs were

performed individually for transformer oil, gas oil, kerosene and vegetable oil
sequence of experiments. Totally, 36 experiments in four blocks and the
experimental results are shown in tables [(4.1)-(4.8)]. Effect parameters (pulse-
on-time and current) on Material Removal Rate (MRR), Electrode Wear Ratio
(EWR), Surface Roughness (SR), White Layer Thickness (WLT), and Micro
Hardness (HV) was determined for each dielectrics separately.
- 55 -
Table (4.1) Experimental results for MRR, EWR, SR, WLT and HV with
transformer oil.
No. of Dielectric Ip Ton Weight of Weight of Weight of Weight of

workpiece workpiece electrode electrode
sample (A) (µs) before (g) after (g) before (g) after (g)
1 Transformer 10 50 18.0297 17.6162 151.9503 151.9036

oil
2 Transformer 10 100 18.0118 17.4809 151.9036 151.8928
oil
3 Transformer 10 200 18.0566 17.3671 151.8928 151.8920

oil
4 Transformer 24 50 18.0714 17.6105 151.8920 151.7562

oil
5 Transformer 24 100 18.0120 17.5893 151.7562 151.6842

oil
6 Transformer 24 200 18.0565 17.4133 151.6844 151.6130

oil
7 Transformer 50 50 18.0609 17.5733 151.6130 151.4444

oil
8 Transformer 50 100 18.0719 17.5484 151.4444 151.2942

oil
9 Transformer 50 200 18.0547 17.4118 151.2942 151.1835

oil
- 56 -
Table (4.2) The experimental results for transformer oil.

No. of Machining MRR EWR SR WLT HV
sample time (mm3/min) (%) (µm) (µm) (Kg/mm²)
(min:sec)
1 4:30 11.5004 0.0307 4.5 5.3 175.6
2 5:35 14.9876 0.0071 5 6.3 180.3
3 5:41 15.5515 0.0005 5.2 9.6 190.2
4 2 24.2130 0.0894 5.9 12.2 200.1
5 2 28.6617 0.0592 6.08 13 205.0
6 3:20 29.0901 0.0470 6.3 13.6 211.3
7 2:16 33.3318 0.1112 7 13.8 218.0
8 2:10 40.0003 0.0991 8.2 14 221.3
9 1:43 46.8735 0.0731 10.4 15.1 224.7
- 57 -
Table (4.3) Experimental results for MRR, EWR, SR, WLT and HV with gas
oil.
No. of Dielectric Ip Ton Weight of Weight of Weight of Weight of

workpiece workpiece electrode electrode
sample (A) (µs) before (g) after (g) before (g) after (g)
1 Gas oil 10 50 18.0631 17.8601 180.0722 180.0585
2 Gas oil 10 100 18.0440 17.8099 180.0585 180.0560
3 Gas oil 10 200 18.0057 17.5562 180.0560 180.0540
4 Gas oil 24 50 18.0595 17.6473 180.0540 179.9540
5 Gas oil 24 100 18.0490 17.5229 179.9540 179.8960
6 Gas oil 24 200 18.0563 17.4981 179.8960 179.8680
7 Gas oil 50 50 18.0628 17.6270 179.8680 179.7186
8 Gas oil 50 100 18.0004 17.7121 179.7186 179.6160
9 Gas oil 50 200 18.0413 17.4467 179.6160 179.518
- 58 -
Table (4.4) The experimental results for gas oil.

(min:sec)
1 5:39 4.4967 0.0076 5.2 4.1 156.3
2 5:21 4.8831 0.0013 5.4 4.8 160.7
3 6:23 8.8178 0.0010 5.5 5.0 164.6
4 4:11 12.3331 0.0555 7.7 7.2 190.4
5 6 14.6327 0.0320 7.9 8.1 196.3
6 4:41 14.9278 0.0157 8.5 8.9 196.1
7 2:23 22.9173 0.0831 9.2 11.0 20.7
8 2:27 24.8845 0.0570 10.2 12.2 212.0
9 2:19 32.3556 0.0541 13 12.5 221.9
- 59 -
kerosene.
No. of Dielectric Ip Ton

Weight of Weight of Weight Weight
workpiece workpiece of of
sample (A) (µs)
before (g) after (g) electrode electrode
before after (g)
(g)
1 Kerosene 10 50 18.0021 17.8689 177.4213 177.4070
2 Kerosene 10 100 18.0062 17.8227 177.4070 177.4060
3 Kerosene 10 200 18.0102 17.5938 177.4065 177.3999
4 Kerosene 24 50 18.0500 17.4744 177.3999 177.2895
5 Kerosene 24 100 18.0092 17.4511 177.2891 177.2395
6 Kerosene 24 200 18.0243 17.4181 177.2395 175.6005
7 Kerosene 50 50 18.0090 17.6170 175.6001 175.4795
8 Kerosene 50 100 18.0175 17.5268 175.4795 175.3999
9 Kerosene 50 200 18.0289 17.4062 175.3999 175.3101
- 60 -
Table (4.6) The experimental results for kerosene.

(min:sec)
1 11 1.5155 0.0080 6.3 0.6 170.0
2 9:2 2.4963 0.0056 7.1 0.8 172.9
3 9 5.7905 0.0037 7.8 1 175.1
4 5:47 8.4572 0.0624 9.5 2.5 192.3
5 5 9.7013 0.0273 9.9 3.9 197.1
6 4:8 10.8385 0.0259 10.4 4.6 199.7
7 2:42 18.1708 0.0689 11.3 5.0 207.2
8 2:1 27.5030 0.0453 12.6 5.9 210.1
9 1:8 30.7934 0.0512 14.3 6.5 220.6
- 61 -
vegetable oil
No. of dielectric Ip Ton

Weight of Weight of Weight Weight
workpiece workpiece of of
sample (A) (µs)
before (g) after (g) electrode electrode
before after (g)
(g)
1 Vegetable 10 50 18.0031 17.7412 174.0201 174.0142
oil
2 Vegetable 10 100 18.0418 17.7246 174.0142 173.9989
oil
3 Vegetable 10 200 18.0215 17.7199 173.9989 173.9865
oil
4 Vegetable 24 50 18.0001 17.6133 173.9865 173.8106
oil
5 Vegetable 24 100 18.0308 17.6099 173.8106 173.7305
oil
6 Vegetable 24 200 17.9924 17.5609 173.7305 173.6362
oil
7 Vegetable 50 50 18.0159 17.5503 173.6362 173.5501
oil
8 Vegetable 50 100 18.0063 17.3103 173.5501 173.4852
oil
9 Vegetable 50 200 17.9908 17.5308 173.4852 173.485
oil
- 62 -
Table (4.8) The experimental results for vegetable oil.

(min:sec)
1 2:44 12.0067 0.0033 3.2 6.6 166.8
2 2:56 15.8798 0.0024 3.7 7.1 171.1
3 1:56 19.5581 0.0013 4.2 8.2 185.2
4 1:50 21.0426 0.0522 5.3 11.9 203.2
5 1:40 32.9239 0.0487 5.5 13.2 210.3
6 1:12 41.2251 0.0465 5.6 13.6 215.1
7 1:24 47.9761 0.0541 6.9 14.2 223.7
8 1:06 67.1293 0.0495 7.2 15.5 230.0
9 0:43 81.0872 0.0374 7.5 17.5 245.9
- 63 -
4.4 Dielectric transformer oil
4.4.1 Effect of pulse-on-time and current on MRR
The effect of pulse-on-time (Ton) on material removal rate (MRR) at

constant pulse-off-time (Toff) value (25 µs) and current (Ip) values (10, 24, 50)
A, as shown in Fig.(4.1). Can be observed MRR increases with increase in Ton
from 50 μs to 200 μs. The reason is increasing discharge energy of plasma
channel and the longer period of the transformation of this energy into the
electrodes which leads to create a high spark with high temperature to melt and
vaporize the material and form bigger craters on the workpiece. It has been
observed that the MRR increases with increasing in I p from 10 A to 50 A. That
is attributed to controlling the input discharge energy where the increase in
current produces strong spark that creates higher temperature leading to melting
and vaporization of material and formation of craters on the workpiece. It can
be noted the maximum MRR value is (46.873 mm3/min) at highest Ton (200 μs)
and highest Ip (50), as shown in table (4.2).
T OFF =25 µs
50
MRR (mm3/min)
40
30
Ip= 10 A
20
Ip=24 A
10
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.1) The effect of Ton and Ip on MRR at constant Toff (25 µs) for
transformer oil.
- 64 -
4.4.2 Effect of pulse-on-time and current on EWR
The effect of pulse-on-time (Ton) on electrode wear rate (EWR) at constant

pulse-off-time (Toff) value (25 µs) and current (Ip) values (10, 24, 50) A, as
shown in Fig.(4.2). Can be observed EWR decrease with an increase in Ton from
50 μs to 200 μs. The reason is that at the beginning of spark, the electron motion
overcomes the ions motion under the wokpiece where the amount of material
removal from the workpiece is more than the tool. Another factor in the
reduction of EWR is the pollution increasing of dielectric liquid with increasing
Ton where the number of sparks drops that leads to the reduction of EWR. It has
been observed that the EWR increases with increasing in I p from 10 A to 50 A.
The EWR increases with increased Ip due to that a higher current produces a
stronger spark causing material to be removed from the electrode. It can be
noted the maximum EWR value is (0.111 %) at lowest Ton (50 μs) and highest
Ip (50 A), as shown in table (4.2).
Tof f =25 µs
0.12
0.1
EWR (%)
0.08
0.06 Ip= 10 A
0.04 Ip=24 A
0.02 Ip= 50 A
0
0 50 100 150 200 250
Ton (µs)
Fig. (4.2) The effect of Ton and Ip on EWR at constant Toff (25 µs) for
transformer oil.
- 65 -
4.4.3 Effect of pulse-on-time and current on SR
The effect of pulse-on-time (Ton) on surface roughness (SR) at constant

shown in Fig. (4.3). Can be observed SR increases with increase in Ton from 50
μs to 200 μs. The smaller SR can be acquired choosing a lower levels Ton, that
is leads to lower temperature for surface machining thereby creating more
surface smoothness and volcanic craters are too small. The performance plots
of SR under the influence of current, It has been observed that the SR increases
with increasing in Ip from 10 A to 50 A. This is because increasing the current
increase the discharge energy and impulsive force, removing more melted
material and generating deeper and larger discharge craters, increasing the
roughness of surface. It can be noted the effect of the Ip is much higher than the
effect of Ton, the maximum SR value is (10.4) at highest Ton (200 μs) and highest
Ip (50 A), as shown in table (4.2).
Tof f =25 µs
11
10
9
SR (µm)
8
Ip= 10 A
7
6 Ip=24 A
5 Ip= 50 A
4
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.3) The effect of Ton and Ip on SR at constant Toff (25 µs) for
transformer oil
- 66 -
4.4.4 Effect of pulse-on-time and current on WLT
The effect of pulse-on-time (Ton) on white layer thickness (WLT) at constant

pulse-off-time (Toff) value (25 µs) and current (Ip) values (10, 24, 50) A, as shown
in Fig.(4.4). Can be observed WLT increases with increase in Ton from 50 μs to
200 μs. The reason of increase in pulse-on-time also provide more time for
conduction of greater amount of heat to the workpiece. Consequently, the
workpiece material is heated to a greater depth and also resulting in a WLT thicker.
It has been observed that the WLT increases with increasing in Ip from 10 A to 50
A. Ip leads to, an increase the discharging energy which was responsible for
producing sparks at the interface between tool and workpiece. Where Ip
constructed the spark responsible for size and depth of the craters. Therefore, the
formation of craters will be bigger, and will increase WLT with high heat. It can
be noted the maximum WLT value is (15.1) at highest Ton (200 μs) and highest Ip
(50 A), as shown in table (4.2).
Tof f =25 µs
16
15
14
13
WLT (µm)
12
11
10 Ip= 10 A
9
8 Ip=24 A
7
6 Ip= 50 A
5
4
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig.(4.4) The effect of Ton and Ip on WLT at constant Toff (25 µs) for
transformer oil.
- 67 -
4.4.5 Effect of pulse-on-time and current on HV
The effect of pulse-on-time (Ton) on micro hardness (HV) at constant pulse-

off-time (Toff) value (25 µs) and current (Ip) values (10, 24, 50) A, as shown in Fig.
(4.5). Can be observed HV increases with increase in Ton from 50 μs to 200 μs.
This is because increase in pulse on-time provides more time for the conduction
of greater amount of heat to the workpiece. Consequently, the workpiece material
is heated to a greater depth due to the presence of high temperature and the same
thickness of the workpiece gets hardened due to quenching during subsequent
spark off. It has been observed that the HV increases with increasing in Ip from 10
A to 50 A. Increase in current leads to increase the temperature of workpiece,
which consequently increases the micro-hardness as it depends on the temperature
of the workpiece before quenching. It can be noted the maximum HV value is
(224.7 Kg/mm²) at highest Ton (200 μs) and highest Ip (50 A), as shown in table
(4.2).
Tof f =25 µs
240
230
HV (kg/mm²)
220
210
200 Ip= 10 A
190 Ip=24 A
180 Ip= 50 A
170
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig.(4.5) The effect of Ton and Ip on HV at constant Toff (25 µs) for
transformer oil.
- 68 -
4.5 Dielectric gas oil

A, as shown in Fig. (4.6). Can be observed MRR increases with increase in Ton
from 50 μs to 200 μs. The reason is the same as for Fig. (4.1). It has been
observed that the MRR increases with increasing in Ip from 10 A to 50 A.
Increase in current values produce strong spark with higher energy that crates
higher temperature due to melting and vaporization of material and formation
of craters on the workpiece. It can be noted the maximum MRR value is (32.355
mm3/min) at highest Ton (200 μs) and highest Ip (50 A), as shown in table (4.4).
Tof f =25 μs
35
MRR (mm3/min)
30
25
20
Ip= 10 A
15
10 Ip=24 A
5 Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (μs)
gas oil.
- 69 -

shown in Fig. (4.7). Can be observed EWR decrease with increase in Ton from
50 μs to 200 μs. The reason is the same as for Fig.(4.2). It can be seen that lowest
value of EWR can be reached at highest value of Ton. It has been observed that
the EWR increases with increasing in Ip from 10 A to 50 A. The EWR increases
with increased Ip due to that a higher current produces a stronger spark causing
material to be removed from the electrode. It can be noted the maximum EWR
value is (0.083 %) at lowest Ton (50 μs) and highest Ip (50 A), as shown in table
(4.4).
Tof f =25 µs
0.1
0.08
EWR (%)
0.06
0.04 Ip= 10 A
0.02 Ip=24 A
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
gas oil.

shown in Fig. (4.8). Can be observed SR increases with increase in Ton from 50
- 70 -
μs to 200 μs. . The reason is the same as for Fig. (4.3). It can be seen that the
highest value of SR can be reached at the highest value of Ton, Ton has the least
effect on SR than effect of current. It has been observed that the SR increases
with increasing in Ip from 10 A to 50 A. This is because more discharge energy
became available at higher levels of current, and resulted in the formation of
large cracks and crater. It can be noted the maximum SR value is (13) at highest
Ton (200 μs) and highest Ip (50 A), as shown in table (4.4).
Tof f =25 µs
14
13
12
11
SR (µs)
10
9 Ip= 10 A
8
7 Ip=24 A
6 Ip= 50 A
5
4
25 50 75 100 125 150 175 200 225
Ton (µs)
gas oil

in Fig. (4.9). Can be observed WLT increases with increase in Ton from 50 μs to
200 μs. The reason is the same as for Fig. (4.4). It can be seen that the highest
value of WLT can be reached at the highest value of Ton. It has been observed that
the WLT increases with increasing in Ip from 10 A to 50 A. Ip leads to, an increase
the discharging energy which was responsible for producing sparks at the interface
- 71 -
between tool and workpiece. Where Ip constructed the spark responsible for size
and depth of the craters. Therefore, the formation of craters will be bigger, and
will increase WLT with high heat. It can be noted the maximum WLT value is
(17.9) at highest Ton (200 μs) and highest Ip (50 A), as shown in table (4.4).
13
Tof f =25 µs
11
WLT ((µm)
9 Ip= 10 A
Ip=24 A
7
Ip= 50 A
5
3
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.9) The effect of Ton and Ip on WLT at constant Toff (25 µs) for
gas oil.

The reason is the same as for Fig. (4.5). It has been observed that the HV increases
with increasing in Ip from 10 A to 50 A. The reason is the same as for Fig. (4.5).
It can be noted the maximum HV value is (221.9 Kg/mm²) at highest Ton (200 μs)
and highest Ip (50 A), as shown in table (4.4).
- 72 -
Tof f =25 µs
230
HV (kg/mm2)
220
210
200
190 Ip= 10 A
180 Ip=24 A
170
160 Ip= 50 A
150
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig.(4.10) The effect of Ton and Ip on HV at constant Toff (25 µs) for
gas oil.
4.6 Dielectric Kerosene

A, as shown in Fig. (4.11). Can be observed MRR increases with increase in Ton
from 50 μs to 200 μs. With increase in Ton spark discharge energy was available
for longer duration, which eventually prolonged melting and evaporation
phenomenon and hence resulted higher MRR. It has been observed that the
MRR increases with increasing in Ip from 10 A to 50 A. This is because more
energy density become available at higher values of current that melt and
removes more materials. It can be noted the maximum MRR value is (30.793
mm3/min) at highest Ton (200 μs) and highest Ip (50 A), as shown in table (4.6).
- 73 -
Tof f =25 µs
35
MRR (mm3/min)
30
25
20
15 Ip= 10 A
10 Ip=24 A
5
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
kerosene.

shown in Fig. (4.12). Can be observed EWR decrease with increase in Ton from
50 μs to 200 μs. The reason is the same as for Fig.(4.2). It can be seen that the
lowest value of EWR can be reached at highest value of T on. It has been
observed that the EWR increases with increasing in I p from 10 A to 50 A. The
EWR increases with increased Ip due to the fact that a higher current will
produce a stronger spark which would cause more material to be eroded from
the electrode. It can be noted the maximum EWR value is (0.068%) at lowest
Ton (50 μs) and highest Ip (50 A), as shown in table (4.6).
- 74 -
Tof f =25 µs
0.08
0.07
EWR (%)
0.06
0.05
0.04 Ip= 10 A
0.03
Ip=24 A
0.02
0.01 Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
kerosene.

shown in Fig. (4.13). Can be observed SR increases with increase in Ton from
50 μs to 200 μs. The reason is the same as for Fig. (4.3). It can be seen that
highest value of SR can reach at the highest value of Ton, Ton which has the least
effect on SR than effect of current. It has been observed that the SR increases
with increasing in Ip from 10 A to 50 A. The current increases, discharge strikes
the surface of the workpiece more intensely, and creates an impact force on the
molten material in the crater and causes more molten material to be ejected out
of the crater, so the surface roughness of the machined surface increases. It can
be noted the maximum SR value is (14.3) at highest Ton (200 μs) and highest Ip
(50 A), as shown in table (4.6).
- 75 -
Ton =25 µs
15
14
13
12
SR (µs) 11
Ip= 10 A
10
9 Ip=24 A
8 Ip= 50 A
7
6
25 50 75 100 125 150 175 200 225
Ton (µs)
kerosene.

in Fig. (4.14). Can be observed WLT increases with increase in Ton from 50 μs to
200 μs. The reason is the same as for Fig. (4.4). It can be seen that highest value
of WLT can reach at the highest value of Ton. It has been observed that the WLT
increases with increasing in Ip from 10 A to 50 A. The reason is the same as for
Fig. (4.4). It can be noted the maximum WLT value is (6.5) at highest Ton (200 μs)
and highest Ip (50 A), as shown in table (4.6).
- 76 -
Ton =25 µs
7
6
WLT (µs)
5
4
Ip= 10 A
3
2 Ip=24 A
1 Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
kerosene.

Increase in pulse on-time provides more time for the conduction of greater amount
of heat to the workpiece. Consequently, the workpiece material is heated to a
greater depth due to thepresence of high temperature and the same thickness of the
workpiece gets hardened due to quenching during subsequent spark off. It has been
observed that the HV increases with increasing in Ip from 10 A to 50 A. The reason
is the same as for Fig. (4.5). It can be noted the maximum HV value is (220.6
Kg/mm²) at highest Ton (200 μs) and highest Ip (50 A), as shown in table (4.6).
- 77 -
Tof f =25 µs
230
HV (kg/mm2)
220
210
200
Ip= 10 A
190
Ip=24 A
180
170 Ip= 50 A
160
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.15) The effect of Ton and Ip on HV at constant Toff (25 µs) for
kerosene.
4.7 Dielectric vegetable oil

A, as shown in Fig.(4.16). MRR increases with an increase in Ton from 50 μs to
200 μs. The reason is increasing the discharge energy of plasma channel and the
longer durations to transformation of this energy into the electrodes which
finally prolonged melting and evaporation phenomenon and hence resulted in
higher MRR for the selected fluids. It has been observed that the MRR increases
with increasing in Ip from 10 A to 50 A. It is attributed to many reasons. With
increase in current values, a greater number of electrons strike the workpiece
and rise the surface temperature. Therefore, more volume of workpiece is
eroded. While, higher current density increases the pressure and temperature
- 78 -
inside the plasma channel, which finally increases the erosion of the work
material. It can be noted the maximum MRR value is (81.087 mm3/min) at
highest Ton (200 μs) and highest Ip (50), as shown in table (4.8).
Tof f =25 µs
MRR (mm3/min)
100
80
60
Ip= 10 A
40
Ip=24 A
20
0 Ip= 50 A
25 50 75 100 125 150 175 200 225
Ton (µs)
vegetable oil.

shown in Fig. (4.17). EWR decrease with increase in Ton from 50 μs to 200 μs.
It is due to the reason that vegetable oil has less number of oxygen atoms than
other dielectrics. It has been observed that the EWR increases with increasing
in Ip from 10 A to 50 A. This behavior is attributed to striking a greater number
of positive ions on electrode surface, which eventually in a higher thermal state
of electrodes contributed to erosion of low melting point electrode material. It
can be noted the maximum EWR value is (0.054) at lowest Ton (50 μs) and
highest Ip (50 A), as shown in table (4.8).
- 79 -
Toff = 25 µs
0.06
0.05
EWR (%)
0.04
0.03 Ip= 10 A
0.02
Ip=24 A
0.01
Ip= 50 A
0
25 50 75 100 125 150 175 200 225
Ton (µs)
vegetable oil.

shown in Fig. (4.18). SR is directly proportional to Ton, The increase of SR is
slightly (0.35 μm) when Ton increases from (50 to 200) μs. Increase in Ton
results increased discharge energy as well as the increased duration for which
this energy is discharged to the workpiece leads to the formation of bigger
craters on the workpiece and thereby surface roughness increases. It has been
observed that the EWR increases with increasing in Ip from 10 A to 50 A. The
surface roughness deteriorated with an increase in the current. This is because
increase in the current increased the discharge energy and impulsive force,
removing more melted material and generating deeper and larger discharge
craters. Hence, the roughness of surface become coarser. It can be noted the
- 80 -
maximum SR value is (7.5) at highest Ton (200 μs) and highest Ip (50 A), as
shown in table (4.8).
Tof f =25 µs
8
7
SR (µs)
6
Ip= 10
5 A
Ip=24 A
4
3
25 50 75 100 125 150 175 200 225
Ton (µs)
vegetable oil.

shown in Fig. (4.19). WLT increases with increase in Ton from 50 μs to 200 μs.
The reason is that increase in pulse-on-time also provides more time for the
conduction of greater amount of heat to the workpiece. Consequently, the
workpiece material is heated to a greater depth and also resulting in a WLT
thicker. It has been observed that the WLT increases with increasing in Ip from
10 A to 50 A. Ip leads to, an increase the discharging energy which was
responsible for producing sparks at the interface between tool and workpiece.
Where Ip constructed the spark responsible for size and depth of the craters.
Therefore, the formation of craters will be bigger, and will increase WLT with
- 81 -
high heat. It can be noted the maximum WLT value is (9.5) at highest Ton (200
μs) and highest Ip (50 A), as shown in table (4.8).
Tof f =25 µs
20
18
WLT (µm) 16
14
Ip= 10 A
12
10 Ip=24 A
8 Ip= 50 A
6
25 50 75 100 125 150 175 200 225
Ton (µs)
vegetable oil.

(4.20). HV increases with increase in Ton from 50 μs to 200 μs. Increase in pulse
on-time is due to high temperature. It provides more time for the conduction of
greater amount of heat to the workpicee. Consequently, the workpiece material is
heated to a greater depth due to the presence of high temperature and the same
thickness of the workpiece gets hardened due to quenching during subsequent
spark off. It has been observed that the HV increases with increasing in Ip from 10
A to 50 A. Increase in current is due to increase the temperature of workpiece,
which consequently increases the micro-hardness as it depends on the temperature
of the workpiece before quenching. It can be noted the maximum HV value is
- 82 -
(245.9 Kg/mm²) at highest Ton (200 μs) and highest Ip (50 A), as shown in table
(4.8).
T of f =25 µs
260
HV (kg/mm²) 250
240
230
220
210
Ip= 10 A
200
190 Ip=24 A
180
170 Ip= 50 A
160
25 50 75 100 125 150 175 200 225
Ton (µs)
Fig. (4.20) The effect of Ton and Ip on HV at constant Toff (25 µs) for
vegetable oil.
4.8 The effect of different dielectric on MRR, EWR, SR, WLT

and HV
4.8.1 Analysis MRR for transformer oil, gas, kerosene and vegetable oil
The material removal rate comparison for transformer oil, gas oil, kerosene
and vegetable oil is shown in Fig.(4.21). It is observed that in the case of
vegetable oil as dielectric, the MRR is the highest value in vegetable oil
followed by transformer oil and gas. However, it is noted that MRR in the case
of gas is slightly better than that of kerosene. The average relative performance
of vegetable oil, transformer oil and gas oil resulted in approximately 163% ,
52% and 5% higher MRR, respectively, compared to kerosene at higher Ton
- 83 -
(200 µs) and higher value of Ip (50 A). The viscosity of EDM dielectric affects
its ability to flush away debris and dissipate heat. A relatively low viscosity
results in better flushing and more effective heat dissipation. For dielectric with
high viscosity, which can restrict the expansion of the discharge channel, the
impulsive force is concentrated within a very small area. Therefore, the removal
effect is enhanced and more debris can be repelled from the crater. Since the
viscosity of vegetable oil is much larger than that of transformer oil, gas oil and
kerosene, the craters obtained in vegetable oil should be bigger and deeper than
those obtained in kerosene. In addition, vegetable oil has a higher dielectric
strength that contributes for higher discharge energy density due to higher
breakdown voltage, which leads to higher molten volume of workpiece. In
kerosene, even though viscosity is less, which is essential for flushing the
debris, high discharge temperature decomposes the kerosene, causing carbon
elements to adhere to the electrode surface, thereby causing lower MRR. Hence,
MRR becomes less in comparison with vegetable oil, transformer oil and gas.
It can be observed from the fig.(4.21) that there is a correlation between gas oil
and kerosene, which is because the value of the viscosity is almost equal to both.
- 84 -
Transformer oil gas oil Vegetable oil kerosene

90
80
70
MRR (mm3/min)
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Experiment number (no.)
Fig. (4.21) Material removal rate comparison between transformer oil, gas oil,
4.8.2 Analysis EWR for transformer oil, gas oil, kerosene and vegetable oil
The electrode wear rate comparison for transformer oil, gas oil, kerosene
vegetable oil as dielectric, the EWR is the lowest value in vegetable oil followed
by kerosene and gas oil. However, it is noted that EWR in the case of gas oil is
much less than that of transformer oil. The average relative performance of
vegetable oil, kerosene and gas oil resulted in approximately 48% , 30% and
26% lower EWR, respectively, compared to transformer oil at higher Ton (200
µs) and higher value of Ip (50 A). The resulted lower EWR in the case of
vegetable oil and kerosene may be due to the deposited carbon layer on the
electrode surface that could have eroded lesser electrode material. Nevertheless,
in transformer oil, oxide layer is deposited at electrode surface which breaks
easily even at lower temperatures which consequently results in higher EWR.
- 85 -
tranformer oil gas oil vegetable oil kerosene

0.12
0.11
0.1
0.09
0.08
EWR (%)
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
0 1 2 3 4 5 6 7 8 9 10
Fig. (4.22) Electrode wear rate comparison between transformer oil, gas oil,
4.8.3 Analysis SR for transformer oil, gas oil, kerosene and vegetable oil
The surface roughness comparison for transformer oil, gas oil, kerosene and
vegetable oil is shown in Fig.(4.23). It is observed that in the case of vegetable
oil as dielectric, the SR is the lowest value in vegetable oil followed by
transformer oil and gas oil. However, it is noted that SR in the case gas slightly
better than that of kerosene. The average relative performance of vegetable oil,
transformer oil and gas oil resulted in approximately 47% , 27 % and 9 % lower
SR, respectively, compared to kerosene at higher Ton (200 µs) and higher value
of Ip (50 A). Owing to its greater viscosity, the vegetable oil had higher flash
point and boiling point than transformer oil, gas oil and kerosene. This
characteristics weakened the capacity of the vegetable oil for heat transmission
and caused the minimal temperature difference in the workpiece. As a result,
- 86 -
the influence of the thermal cycling stress on the workpiece was relatively
small, and the micro-cracks produced on the surface were few and fine. The
viscosity of kerosene is lowered almost 13 to 14 times that of vegetable oil and
also has a very low flash point and boiling point. Which produces a cloud of
vapors and bubbles at low temperatures. Which eliminates fluid action and
becomes like welding process, thus producing more cracks on the surface.
Transformer oil Gas oil Vegetable oil kerosene
15
14
13
12
11
SR (µm)
10
9
8
7
6
5
4
3
2
0 1 2 3 4 5 6 7 8 9 10
Experiment number(no.)
Fig. (4.23) Surface roughness comparison between transformer oil, gas oil,
4.8.4 Analysis WLT for transformer oil, gas oil, kerosene and vegetable oil
The white layer thickness comparison for transformer oil, gas oil, kerosene
kerosene as dielectric, the WLT is the lowest value in kerosene followed by gas
oil, transformer oil and vegetable oil. The average relative performance of
kerosene, gas oil and transformer oil resulted in approximately 62%, 28% and
- 87 -
14% lower WLT, respectively, compared to vegetable oil at higher Ton (200 µs)
and higher value of Ip (50 A). This phenomenon is explained by the fact that the
amount of molten metal that can be flushed away by different dielectrics is
different. Therefore, as vegetable oil emulsion has higher viscosity than
kerosene, it cannot clear away the molten material, and so it builds up on the
surface of the sample. During subsequent cooling, this molten material
resolidifies to form the white layer, the depth of which depends on the volume
of molten material that was left on the sample surface during machining.
Standard deviations for measured white layer thicknesses indicate that
increasing the discharge energy increases the white layer thickness deviation
considerably. It can be observed from the Fig. (4.24) the correlation of vegetable
oil at some points with transformer oil due to the high cooling rate of the
transformer oil.
Transformer oil Gas oil Vegetable oil kerosene

18
16
14
12
10
WLT (µm)
8
6
4
2
0
0 1 2 3 4 5 6 7 8 9 10
Fig. (4.24) White layer thickness comparison between transformer oil, gas oil,
- 88 -
4.8.5 Analysis HV for transformer oil, gas oil, kerosene and vegetable oil
The micro-hardness comparison for transformer oil, gas oil, kerosene and
vegetable oil is shown in Fig.(4.25). It is observed that in the case of kerosene
as dielectric, the HV is the highest value in vegetable oil followed by
transformer oil, gas oil and kerosene. The average relative performance of
vegetable oil, transformer oil and gas oil resulted in approximately 11%, 2%
and 0.5% higher HV, respectively, compared to kerosene for the same set of
parameters. The high cooling rate is the reason for the hardness increase of the
white layer when machining performed in vegetable oil, since the high cooling
rate can make the white layer freeze into a martensitic- austenitic structure
which is also known to give a high hardness. On the other hand, vegetable oil
contains the nitrogen atoms, which are carried out to the surface of the
workpiece forming solid solution. Where nitrogen atoms contribute to give a
high hardness of the surface (Nitriding). In general, the hardness increases
slightly because the metal used in machining is stanless steel 316L.
tranformer oil gas oil vegetable oil kerosene
250
240
230
HV (kg/mm2)
220
210
200
190
180
170
160
150
0 1 2 3 4 5 6 7 8 9 10
Expermental number (no.)
Fig. (4.25) Micro-hardness comparison between transformer oil, gas oil,

- 89 -
4.9 Models of Different dielectric

The purpose of the experimentation is to create statistical models for
transformer oil, gas oil, kerosene and vegetable oil dielectric to create plots to
determine effect different dielectric performs using 32 (level factor) full factorial
design. The two selected factors for the experiments are the controllable
variables that have a main role to play in the process of characterization which
includes pulse on time with three numeric levels of (50, 100, 200) and current
with three numeric levels of (10, 24, and 50) and one for number of replicates.
The general full factorial design with confidence interval of 95% analyzes the
experimented values by Minitab statistical software with general linear model.
4.9.1.a. Analyzing factorial designs for MRR
Entering the response data (MRR), analyzing of factorial designs were
performed to fit models for the data that generates residual plots to assess the
importance of the effects such as normal probability plots between the residuals
versus their expected values when the distribution is normal using regression
and ANOVA. They show an obvious pattern (i.e. the points have been stabilized
in a straight line) which indicates that each factor affects the MRR in the four
dielectric and the results of the MRR from the regression model (predicted value
by the factorial) and the true values (from experiments) are shown in tables
[(4.9)-(4.12)]. The plots of normal probability of residuals for MRR are shown
in Fig. (4.26 (a, b, c and d)) for transformer oil, gas oil, kerosene and vegetable
oil, respectively.
- 90 -
Table (4.9) Values of experimented and predicted MRR for transformer oil.
No. of Measured MRR Predicted MRR Residual

exp. values (mm³/min) values (mm3/min) values
1 29.090 30.6910 -1.6010

2 14.987 14.7613 0.2256
3 15.550 17.3833 -1.8333
4 33.330 35.9477 -2.6176
5 28.660 28.0690 0.5910
6 24.210 23.2000 1.0100
7 11.500 9.8923 1.6076
8 40.000 40.8167 -0.8166
9 46.873 43.4387 3.4343
Table (4.10) Values of experimented and predicted MRR for gas oil.
exp. values(mm³/min) values(mm3/min) values
1 14.9278 17.1246 -2.1967

2 4.4967 5.0680 -0.5712
3 8.8178 9.0973 -0.2794
4 22.9173 24.4280 -1.5106
5 14.6321 13.0953 1.5368
6 12.3331 11.6732 0.6599
7 4.4967 3.6459 0.8507
8 24.8845 25.8501 -0.9655
9 32.3556 29.8794 2.4762
- 91 -
Table (4.11) Values of experimented and predicted MRR for kerosene.

exp. values (mm³/min) values (mm3/min) values
1 10.8385 12.6657 -1.82724

2 2.4963 3.6936 -1.1972
3 5.7905 6.2675 -0.4770
4 18.1708 22.0629 -3.8920
5 9.7013 10.0918 -0.3905
6 8.4572 6.2395 2.2177
7 1.5155 -0.1588 1.6743
8 27.5030 25.9152 1.5877
9 30.7934 28.4891 2.3042
Table (4.12) Values of experimented and predicted MRR for vegetable oil.
exp. values values (mm3/min) values
(mm³/min)
1 41.2251 41.3730 -0.14792

2 15.8798 16.8116 -0.9317
3 19.5581 25.4574 -5.89926
4 47.9761 54.7584 -6.78226
5 32.9239 32.7272 0.19668
6 21.0426 21.0914 -0.04876
7 12.0067 5.1757 6.83101
8 67.1293 66.3942 0.73508
9 81.0872 75.0400 6.04718
- 92 -
(a) (c)
(b) (d)
Fig. (4.26) The normal probability plots of residuals for MRR for: (a)
Transformer oil (b) gas oil (c) kerosene, and (d) vegetable oil.
Figs. [(4.27)-(4.30)] compares the experimented and predicted values of

MRR. The nearness of both experimented and predicted MRR curves indicates
that the experimented and predicted MRR values are approximately equal.
- 93 -
Experimented MRR Predicted MRR
50
45
40
MRR (mm3/min)
35
30
25
20
15
10
5
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.27) Comparison of experimented and predicted MRR values for

transformer oil.
35
30
MRR (mm3/min)
25
20
15
10
5
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.28) Comparison of experimented and predicted MRR values for gas
oil.
- 94 -
35
30
MRR (mm3/min)
25
20
15
10
0
1 2 3 4 5 6 7 8 9
-5
Experiment number

kerosene.
90
80
70
MRR (mm3/min)
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9

vegetable oil.
The output of analysis of variance (ANOVA) are arranged in a table that

includes the sources of variation, the degrees of freedom (DF), the total sum of
squares (Adj SS), the mean squares (Adj MS), the F-values and P-values to
- 95 -
determine whether the factors are significantly related to the response, as shown
in tables [(4.13)-(4.16)] for transformer oil, gas oil, kerosene and vegetable oil,
respectively.
Table (4.13) ANOVA table for MRR for transformer oil.
Source DF Adj SS Adj MS F-Value P-Value
Model 4 1105.17 276.294 37.79 0.002
Linear 4 1105.17 276.249 37.79 0.002
Ton 2 86.70 43.349 5.93 0.064
Ip 2 1018.48 509.239 96.66 0.001
Error 4 29.24 7.311
Total 8 1134.42
Table (4.14) ANOVA table for MRR for gas oil.
Model 4 706.99 176.748 39.09 0.002
Linear 4 706.99 176.748 39.07 0.002
Ton 2 47.97 23.987 5.30 0.075
Ip 2 659.02 329.508 72.83 0.001
Error 4 18.10 4.524
Total 8 725.09
- 96 -
Table (4.15) ANOVA table for MRR for kerosene.

Model 4 4466.7 1116.68 26.99 0.004
Linear 4 4466.7 1116.68 26.99 0.004
Ton 2 621.5 310.74 7.51 0.044
Ip 2 3845.2 1922.61 46.47 0.002
Error 4 165.5 41.38
Total 8 4632.2
Table (4.16) ANOVA table for MRR for vegetable oil

Model 4 847.88 211.970 23.65 0.005
Linear 4 847.88 211.970 23.65 0.005
Ton 2 62.76 31.381 3.50 0.132
Ip 2 785.12 392.559 43.80 0.002
Error 4 35.85 8.963
Total 8 883.73
4.9.1.b. Determining Degree of Regression Model for MRR

These coefficients were used to develop the mathematical model, the
mathematical relation between input parameters and MRR for correlating MRR
- 97 -
has been obtained in regression equations for transformer oil, gas oil, kerosene,
vegetable oil as shown in equations of [(4.1)-(4.4)].
MRR1 = 27.133 - 4.12 Ton (50) + 0.75 Ton (100) + 3.37 Ton (200) - 13.12 Ip
(10) + 0.19 Ip (24) + 12.93 Ip (50) ……………… (4.1)
MRR2= 15.540 - 2.29 Ton (50) - 0.87 Ton (100) + 3.16 Ton (200) - 9.60 Ip (10)
- 1.58 Ip (24) + 11.18 Ip (50) ..………………(4.2)
MRR3= 12.807 - 3.43 Ton (50) + 0.43 Ton (100) + 3.00 Ton (200) - 9.54 Ip (10)
- 3.14 Ip (24) + 12.68 Ip (50) ………………… (4.3)
MRR4 = 37.65 - 10.64 Ton (50) + 1.00 Ton (100) + 9.64 Ton (200) - 21.83 Ip
(10) - 5.92 Ip (24) + 27.75 Ip (50) ………………… (4.4)
4.9.1.c. Model summary

Model Summary displays the statistics that compare how well different
models fit the data. Where R -Square (R-Sq) describes the amount of variation
in the observed responses that is explained by the model, it is also known as the
coefficient of determination. Adjusted R-square (R-Sq (adj)) of is a modified R
that has been adjusted for the number of terms in the model. The predicted R-
square (R-Sq (pred)) reflects how well the model will predict future data. Higher
values of R -Square (R-Sq) and adjusted R-square (R-Sq (adj)) indicate a better
fit. The information about the four models for transformer oil, gas oil, kerosene
and vegetable oil in output of session windows is shown in tables [(4.17)-
(4.20)].
- 98 -
Table (4.17) Model summary for MRR for transformer oil.
S R-sq R-sq(adj) R-sq(pred)

2.70384 97.42% 94.84% 86.95%
Table (4.18) Model summary for MRR for gas oil.

2.12707 95.01% 95.01% 87.36%
Table (4.19) Model summary for MRR for kerosene.

2.99386 95.94% 91.98% 79.46%
Table (4.20) Model summary for MRR for vegetable oil.
6.43239 96.43% 92.85% 81.91%
4.9.2.a. Analyzing factorial designs for EWR

Entering the response data (EWR), analyzing factorial designs were
performed to fit the models for the data that generates residual plots to assess
the importance of the effects such as normal probability plots between the
residuals versus their expected values when the distribution is normal using
regression and ANOVA. They show an obvious pattern (i.e. the points have
been stabilized in a straight line) which indicates that each factor affects the
EWR in the four dielectric and the results of the EWR from the regression model
(predicted values by the factorial) and the true values (from experiments) are
shown in tables [(4.21)-(4.24)]. . The plots of normal probability of residuals
for EWR are shown in Fig. (4.31 (a, b, c and d)) for transformer oil, gas oil,
kerosene and vegetable oil, respectively.
- 99 -
Table (4.21) Values of experimented and predicted EWR for transformer oil.
No. of Measured Predicted Residual
exp. EWR (%) EWR (%) values
1 0.0005 -0.004511 0.0050111

2 0.0470 0.047922 -0.0009222
3 0.0991 0.092122 0.0069778
4 0.0894 0.084822 0.0045778
5 0.1112 0.114089 -0.0028889
6 0.0307 0.032389 -0.0016889
7 0.0071 0.010422 -0.0033222
8 0.0592 0.062856 -0.0036556
9 0.0731 0.077189 -0.0040889
Table(4.22) Values of experimented and predicted EWR for gas oil.
1 0.0010 -0.0072444 0.0082444

2 0.0157 0.0238556 -0.0081556
3 0.0570 0.0606889 -0.0036889
4 0.0555 0.0489889 0.0065111
5 0.0831 0.0793222 0.0037778
6 0.0076 0.0178889 -0.0102889
7 0.0013 -0.0007444 0.0020444
8 0.0320 0.0303556 0.0016444
9 0.0541 0.0541889 -0.0000889
- 100 -
Table (4.23) Values of experimented and predicted EWR for kerosene.

1 0.00372 -0.0004211 0.0041411

2 0.02590 0.0323422 -0.0064422
3 0.04536 0.0481189 -0.0027589
4 0.06240 0.0518356 0.0105644
5 0.06890 0.0684422 0.0004578
6 0.00805 0.0190722 -0.0110222
7 0.00563 -0.0012511 0.0068811
8 0.02739 0.0315122 -0.0041222
9 0.05125 0.0489489 0.0023011
Table(4.24) Values of experimented and predicted EWR for vegetable oil.
1 0.0013 0.0023333 -0.0010333

2 0.0465 0.0491333 -0.0026333
3 0.0495 0.0470000 0.0025000
4 0.0522 0.0491333 0.0030667
5 0.0541 0.0470000 0.0071000
6 0.0033 0.0023333 0.0009667
7 0.0024 0.0023333 0.0000667
8 0.0487 0.0491333 -0.0004333
9 0.0374 0.0470000 -0.0096000
- 101 -
(a) (c)
(b) (d)
Fig. (4.31) The normal probability plots of residuals for EWR for (a)
transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.
Figs. [(4.32)-(4.35)] compare the experimented and predicted values of

EWR. The nearness of both experimented and predicted EWR curves indicates
that their values are approximately equal.
- 102 -
Experimented EWR Predicted EWR
0.14
0.12
0.1
0.08
EWR (%)
0.06
0.04
0.02
0
-0.02 1 2 3 4 5 6 7 8 9
Experimented number
Fig. (4.32) Comparison of experimented and predicted EWR values for

transformer oil.
0.09
0.08
0.07
0.06
0.05
EWR (%)
0.04
0.03
0.02
0.01
0
-0.01 1 2 3 4 5 6 7 8 9
-0.02
Experiment number
Fig. (4.33) Comparison of experimented and predicted EWR values for gas
oil.
- 103 -
0.08
0.07
0.06
0.05
EWR (%)
0.04
0.03
0.02
0.01
0
-0.01 1 2 3 4 5 6 7 8 9
Experimented number

kerosene.
0.08
0.07
0.06
0.05
EWR (%)
0.04
0.03
0.02
0.01
0
1 2 3 4 5 6 7 8 9
Experiment number

vegetable oil.

includes the sources of variation, the degrees of freedom (DF). The total sum of
- 104 -
respectively.
Table (4.25) ANOVA table for EWR for transformer oil.
Model 4 0.012348 0.00308 83.47 0.000
Linear 4 0.012348 0.00308 83.47 0.000
Ton 2 0.002067 0.00103 27.95 0.004
Ip 2 0.010281 0.00514 139.00 0.000
Error 4 0.000148 0.00003
Total 8 0.012496
Table (4.26) ANOVA table for EWR for gas oil.
DF Adj SS Adj MS F-Value P-Value
Model 4 0.0066 0.0016 21.05 0.006
Linear 4 0.0068 0.0016 21.05 0.006
Ton 2 0.0010 0.0005 6.43 0.056
Ip 2 0.0056 0.0028 35.65 0.003
Error 4 0.0003 0.0000
Total 8 0.0070
- 105 -
Table (4.27) ANOVA table for EWR for kerosene.

Model 4 0.0045 0.0011 12.41 0.016
Linear 4 0.0045 0.0011 12.41 0.016
Ton 2 0.0007 0.0003 4.30 0.101
Ip 2 0.0037 0.0018 20.51 0.008
Error 4 0.0003 0.0049
Total 8 0.0049
Table (4.28) ANOVA table for EWR for vegetable oil.

Model 2 4466.7 1116.68 26.99 0.004
Linear 2 4466.7 1116.68 26.99 0.004
Ton 2 621.5 310.74 7.51 0.044
Ip 3845.2 1922.61 46.47 0.002
Error 4 165.5 41.38
Total 8 4632.2
4.9.2.b Determining Degree of Regression Model for EWR

mathematical relation between input parameters and EWR for correlating EWR
has been obtained in regression equations for transformer oil, gas oil, kerosene
- 106 -
and vegetable oil, as shown in equations of (4.5), (4.6), (4.7), and(4.8),

respectively.
EWR1 = 0.05748 + 0.01962 Ton (50) - 0.00234 Ton (100) - 0.01728 Ton (200)
- 0.04471 Ip (10) + 0.00772 IP (24) + 0.03699 IP (50) ………….. (4.5)
EWR2 = 0.03414 + 0.01459 Ton (50) - 0.00404 Ton (100) - 0.01054 Ton (200)
- 0.03084 Ip (10) + 0.00026 Ip (24) + 0.03059 Ip (50) …………. (4.6)
EWR3 = 0.03318 + 0.01327 Ton (50) - 0.00705 Ton (100 )- 0.00622 Ton
(200)- 0.02738 Ip (10) + 0.00539 Ip (24) + 0.02199 Ip (50) …………. (4.7)
EWR4 = 0.03282 - 0.03049 Ip (10) + 0.01631 Ip (24) + 0.01418 Ip (50) … (4.8)

Model summary displays the statistics that compare how well different
models fit the data. Where R -Square (R-Sq) of describes the amount of
variation in the observed responses that is explained by the model, it is also
known as the coefficient of determination. Adjusted R-square (R-Sq (adj)) of is
a modified R that has been adjusted for the number of terms in the model. The
predicted R-square (R-Sq (pred)) reflects how well the model will predict future
data. Higher values of R -Square (R-Sq) and adjusted R-square (R-Sq (adj))
indicate a better fit. The information about the four models for transformer oil,
gas oil, kerosene and vegetable oil in output of session windows is shown in
tables [(4.29)-(4.32)].
Table (4.29) Model summary for EWR for transformer oil.

0.0060812 98.82% 97.63% 94.01%
- 107 -
Table (4.30) Model summary for EWR for gas oil.

0.0089094 95.46% 90.93% 77.04%
Table (4.31) Model summary for EWR for kerosene.

0.0096074 92.54% 85.08% 62.24%
Table (4.32) Model summary for EWR for vegetable oil.

0.0052813 96.16% 94.88% 91.36%
4.9.3.a. Analyzing factorial designs for SR

Entering the response data (SR), analyzing of factorial designs were
performed to fit models for the data that generates residual plots to assess the
and ANOVA They show an obvious pattern (i.e. the points have been stabilized
in a straight line) which indicates that each factor affect the SR in the four
dielectric and the results of the SR from the regression model (predicted values
[(4.33)-(4.36)]. The plots of normal probability of residuals for SR are shown
oil, respectively.
- 108 -
Table (4.33) Values of experimented and predicted SR for transformer oil.

No. of Measured Predicted SR Residual
exp. SR(µm) (µm) values
1 7.0 8.5 -1.5

2 6.0 6.0 -0.0
3 8.2 8.5 -0.3
4 4.5 4.9 -0.4
5 5.0 4.9 0.1
6 5.2 4.9 0.3
7 5.9 6.0 -0.1
8 10.4 8.5 1.8
9 6.3 6.0 0.2
Table(4.34) Values of experimented and predicted SR for gas oil.
No. of Measured SR Predicted SR Residual
exp. (µm) values
(µm)
1 9.2 10.8 -1.6

2 7.9 8.0 -0.1
3 10.2 10.8 -0.6
4 5.2 5.3 -0.1
5 5.4 5.3 0.1
6 5.5 5.3 0.2
7 7.7 8.0 -0.3
8 13.0 10.8 2.2
9 8.5 8.0 0.4
- 109 -
Table (4.35) Values of experimented and predicted SR for kerosene.

No. of Measured Predicted SR Residual
exp. SR(µm) (µm) values
1 11.3 11.8 -0.5

2 9.9 9.8 0.1
3 12.6 12.6 0.0
4 6.3 6.1 0.2
5 7.1 7.0 0.1
6 7.8 7.9 -0.1
7 9.5 9.0 0.5
8 14.3 13.6 0.6
9 10.4 10.8 -0.4
Table (4.36) Values of experimented and predicted SR for vegetable oil.
No. of Measured SR Predicted SR Residual
exp. (µm) values
(µm)
1 14.2 12.6 1.6

2 5.5 5.4 0.1
3 7.2 9.6 -2.4
4 3.2 3.7 -0.5
5 3.7 3.7 0.0
6 4.2 3.7 0.5
7 5.3 5.4 -0.1
8 7.5 7.6 -0.1
9 5.6 5.4 0.1
- 110 -
(a) (c)
(b) (d)
Fig. (4.36) The normal probability plots of residuals for SR for (a)
transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.

SR. The nearness of both experimented and predicted SR curves indicates that
the experimented and predicted SR values are approximately equal.
- 111 -
Experimented SR Predicted SR
12
10
8
SR (µm)
6
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.37) Comparison of experimented and predicted SR values for

transformer oil.
14
12
10
SR(µm)
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.38) Comparison of experimented and predicted SR values for gas oil.
- 112 -
16
14
12
SR(µm) 10
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.39) Comparison of experimented and predicted SR values for kerosene.
16
14
12
10
SR (µm)
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.40) Comparison of experimented and predicted SR values for vegetable

oil.
- 113 -

respectively.
Table (4.37) ANOVA table for SR for transformer oil.
Model 2 20.647 10.323 9.84 0.013
Linear 2 20.647 10.323 9.84 0.013
Ip 2 20.647 10.323 9.84 0.013
Error 6 6.293 1.049
Total 8 26.940
Table (4.38) ANOVA table for SR for gas oil.
Model 2 44.287 22.143 16.30 0.004
Linear 2 44.287 22.143 16.30 0.004
Ip 2 44.287 22.143 16.30 0.004
Error 6 8.153 1.359
Total 8 52.440
- 114 -
Table (4.39) ANOVA table for SR for kerosene.
Model 4 53.083 13.2594 44.53 0.006
Linear 4 53.083 13.2594 44.53 0.006
Ton 2 4.869 2.4344 8.18 0.056
Ip 2 48.196 24.0844 80.88 0.003
Error 4 1.191 0.2978
Total 8 54.229
Table (4.40) ANOVA table for MRR for vegetable oil.

Model 2 55.69 27.843 5.24 0.005
Linear 2 55.69 27.843 5.24 0.005
Ip 2 55.69 27.843 5.24 0.005
Error 6 31.87 5.312
Total 8 87.56
4.9.3.b. Determining Degree of Regression Model for SR

These coefficients were used to develop the mathematical model. The
mathematical relation between input parameters and SR for correlating SR has
been obtained in regression equations for transformer oil, gas oil, kerosene and
- 115 -
vegetable oil, as shown in equations of (4.9), (4.10), (4.11), and (4.12),

respectively.
SR1 = 6.500 - 1.600 IP (10) - 0.433 IP (24) + 2.033 IP (50) ...…… (4.9)
SR2 = 8.067 - 2.700 IP (10) - 0.033 IP (24) + 2.733 IP (50) ……. (4.10)
SR3 = 9.911 - 0.878 Ton (50) - 0.044 Ton (100) + 0.922 Ton (200) - 2.844 IP (10)
+ 0.022 IP (24) + 2.822 IP (50) …… (4.11)
SR4 = 6.267 - 2.57 IP (10) - 0.80 IP (24) + 3.37 IP (50) ……… (4.12)

Model Summary displays the statistics that compares how well different
models fit the data. Where R -Square (R-Sq) describes the amount of variation
in the observed responses that is explained by the model, it is also known as the
coefficient of determination. Adjusted R-square (R-Sq (adj)) of is a modified R
that has been adjusted for the number of terms in the model. The predicted R-
square (R-Sq (pred)) reflects how well the model will predict future data. Higher
values of R -Square (R-Sq) and adjusted R-square (R-Sq (adj)) indicate a better
fit. The information about the four models for transformer oil, gas oil, kerosene
and vegetable oil in output of session windows is shown in tables [(4.41)-
(4.44)].
Table (4.41) Model summary for SR for transformer oil.
S R-sq R-sq (adj) R-sq (pred)

1.02415 76.64% 68.85% 47.44%
- 116 -
Table (4.42) Model summary for SR for gas oil.

1.16571 84.45% 79.27% 65.02%
Table (4.43) Model summary for SR for kerosene.

0.545690 97.80% 95.61% 88.88%
Table (4.44) Model summary for SR for vegetable oil.

1.2013 86.45% 80.27% 70.02%
4.9.4.a. Analyzing factorial designs for WLT

Entering the response data (WLT), analyzing of factorial designs were
performed to fit models for the data that generate residual plots to assess the
in a straight line) which indicates that each factor affects the WLT in the four
dielectric and the results of the WLT from the regression model (predicted value
[(4.45)-(4.46)]. The plots of normal probability of residuals for WLT are shown
oil, respectively.
- 117 -
Table (4.45) Values of experimented and predicted WLT for transformer oil.
No. of Measured WLT Predicted WLT Residual
exp. values(µm) values(µm) values
1 13.0 11.6000 1.40000

2 9.6 7.0667 2.53333
3 13.8 14.3000 -0.50000
4 12.2 11.6000 0.60000
5 14.0 14.3000 -0.30000
6 15.1 14.3000 0.80000
7 6.3 7.0667 -0.76667
8 5.3 7.0667 -1.76667
9 9.6 11.6000 -2.00000
Table (4.46) Values of experimented and predicted WLT for gas oil.
values(µm) values(µm) values
exp.
1 8.1 8.2333 -0.133333

2 5.0 5.2333 -0.233333
3 11.0 11.1333 -0.133333
4 7.2 7.3000 -0.100000
5 12.2 12.0667 0.133333
6 12.5 12.5000 0.000000
7 4.8 4.8000 0.000000
8 4.1 3.8667 0.233333
9 8.9 8.6667 0.233333
- 118 -
Table (4.47) Values of experimented and predicted WLT for kerosene.

1 3.9 3.77778 0.122222

2 1.0 1.41111 -0.411111
3 5.0 5.07778 -0.077778
4 2.5 2.94444 -0.444444
5 5.9 5.91111 -0.011111
6 6.5 6.41111 0.088889
7 0.8 0.91111 -0.111111
8 0.6 0.07778 0.522222
9 4.6 4.27778 0.322222
Table (4.48) Values of experimented and predicted WLT for vegetable oil.
1 13.2 12.8556 0.344444

2 8.2 8.4222 -0.222222
3 14.2 14.6556 -0.455556
4 11.9 11.8222 0.077778
5 15.5 15.6889 -0.188889
6 17.5 16.8556 0.644444
7 7.1 7.2556 -0.155556
8 6.6 6.2222 0.377778
9 13.6 14.0222 -0.422222
- 119 -
(a) (c)
(b) (d)
Fig. (4.41) The normal probability plots of residuals for WLT for
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.

WLT. The nearness of both experimented and predicted WLT curves indicates
that the experimented and predicted WLT values are approximately equal.
- 120 -
Experimented WLT Predicted WLT
16
14
WLT (µm) 12
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experimentel number
Fig. (4.42) Comparison of experimented and predicted WLT values for

transformer oil.
14
12
10
WLT (µm)
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.43) Comparison of experimented and predicted WLT values for gas oil.
- 121 -
7
6
5
WLT(µm) 4
3
2
1
0
1 2 3 4 5 6 7 8 9
Experiment number

kerosene.
16
14
12
WLT (µm)
10
8
6
4
2
0
1 2 3 4 5 6 7 8 9
Experimentel number

vegetable oil.

- 122 -
in Tables [(4.49)-(4.52)] for transformer oil, gas oil, kerosene and vegetable oil,
respectively.
Table (4.49) ANOVA table for WLT for transformer oil.

2 80.16 40.081 13.80 0.006

Model
2 80.16 40.081 13.80 0.006

Linear
2 80.16 40.081 13.80 0.006

Ip
6 17.43 2.904
Error
8 97.59
Total
Table (4.50) ANOVA table for WLT for gas oil.

Model 4 82.2133 20.5533 362.71 0.000
Linear 4 82.2133 20.5533 362.71 0.000
Ton 2 2.9267 1.4633 25.82 0.005
Ip 2 79.2867 39.6433 699.59 0.000
Error 4 0.2267 0.0567
Total 8 82.4400
- 123 -
Table (4.51) ANOVA table for WLT for kerosene.

Model 4 40.4911 10.1228 51.62 0.001
Linear 4 40.4911 10.1228 51.62 0.001
Ton 2 2.7222 1.3611 6.94 0.050
Ip 2 37.7689 18.8844 96.29 0.000
Error 4 0.7844 0.1961
Total 8 41.2756
Table (4.52) ANOVA table for WLT for vegetable oil.

Model 4 117.778 29.4444 100.00 0.000
Linear 4 117.778 29.4444 100.00 0.000
Ton 2 7.269 3.6344 12.34 0.019
Ip 2 110.509 55.2544 178.66 0.000
Error 4 1.178 0.2944
Total 8 118.659
4.9.4.b.Determining Degree of Regression Model for WLT

mathematical relation between input parameters and WLT for correlating WLT
has been obtained in regression equations for transformer oil, gas oil, kerosene
- 124 -
and vegetable oil, as shown in equations of (4.13),(4.14),(4.15), and(4.16),

respectively.
WLT1 = 10.989 - 3.922 IP (10) + 0.611 IP (24) + 3.311 IP (50) ………. (4.13)
WLT2 = 8.2000 - 0.767 Ton (50) + 0.167 Ton (100) + 0.600 Ton (200) - 3.567 IP
(10) - 0.133 IP (24) + 3.700 IP (50) ……….. (4.14)
WLT3 = 3.422 - 0.722 Ton (50) + 0.111 Ton (100) + 0.611 Ton (200) - 2.622 IP
(10)+ 0.244 IP (24)+ 2.378 IP (50) ……….. (4.15)
WLT4 = 11.978 - 1.078 Ton (50)- 0.044 Ton (100)+ 1.122 Ton (200)- 4.678 IP
(10)+ 0.922 IP (24)+ 3.756 IP (50) ………. (4.16)

Model Summary displays the statistics that compare how well different
Tables (4.53), (4.54), (4.55) and (4.56), respectively.
Table (4.53) Model summary for WLT for transformer oil.

1.70424 82.14% 76.19% 59.82%
- 125 -
Table (4.54) Model summary for WLT for gas oil.

0.238048 99.13% 98.45% 98.61%
Table (4.55) Model summary for WLT for kerosene.

0.442844 98.10% 96.20% 90.38%
Table (4.56) Model summary for WLT for vegetable oil.

0.542627 99.73% 99.45% 94.99%
4.9.5.a. Analyzing factorial designs for HV

Entering the response data (HV), analyzing factorial designs were
performed to fit models for the data that generate residual plots to assess the
in a straight line) which indicates that each factor affect the HV in the four
dielectric and the results of the HV from the regression model (predicted values
[(4.57)-(4.60)]. The plots of normal probability of residuals for HV are shown
oil, respectively.
- 126 -
Table (4.57) Values of experimented and predicted HV for transformer oil.

No. of Measured HV Predicted HV Residual
exp. (kg/mm2) (kg/mm2) values
1 218.0 216.289 1.71111

2 175.6 176.989 -1.38889
3 180.3 181.289 -0.98889
4 200.1 200.422 -0.32222
5 205.0 204.722 0.27778
6 211.3 211.256 0.04444
7 190.2 187.822 2.37778
8 224.7 227.122 -2.42222
9 221.3 220.589 0.71111
Table(4.58) Values of experimented and predicted HV for gas oil.
1 200.7 205.222 -4.52222

2 156.3 154.222 2.07778
3 160.7 161.422 -0.72222
4 190.4 187.956 2.44444
5 196.3 195.156 1.14444
6 196.1 199.689 -3.58889
7 164.6 165.956 -1.35556
8 221.9 216.956 4.94444
9 212.0 212.422 -0.42222
- 127 -
Table (4.59) Values of experimented and predicted HV for kerosene.

1 207.2 208.578 -1.37778

2 170.0 168.611 1.38889
3 172.9 172.144 0.75556
4 192.3 192.311 -0.01111
5 197.1 195.844 1.25556
6 199.7 200.944 -1.24444
7 175.1 177.244 -2.14444
8 220.6 217.211 3.38889
9 210.1 212.111 -2.01111
Table(4.60) Values of experimented and predicted HV for vegetable oil.
exp. values
( kg/mm2) ( kg/mm2)
1 223.7 225.400 -1.70000

2 166.8 166.567 0.23333
3 171.1 172.467 -1.36667
4 203.2 201.733 1.46667
5 210.3 207.633 2.66667
6 215.1 219.233 -4.13333
7 185.2 184.067 1.13333
8 245.9 242.900 3.00000
9 230.0 231.300 -1.30000
- 128 -
(a) (c)
(b) (d)
Fig. (4.46) The normal probability plots of residuals for HV for
: (a) transformer oil, (b) gas oil, (c) kerosene, and (d) vegetable oil.

HV. The nearness of both experimented and predicted HV curves indicates that
the experimented and predicted HV values are approximately equal.
- 129 -
Experimented HV Predicted HV
250
200
HV (kg/mm2) 150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.47) Comparison of experimented and predicted HV values for

transformer oil.
250
200
HV (kg/mm2)
150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number
Fig. (4.48) Comparison of experimented and predicted HV values for gas oil.
- 130 -
250
200
HV (kg/mm2) 150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number

kerosene.
300
250
HV (kg/mm2)
200
150
100
50
0
1 2 3 4 5 6 7 8 9
Experiment number

vegetable oil.
- 131 -

in Tables [(4.61)-(4.64)] for transformer oil, gas oil, kerosene and vegetable oil,
respectively.
Table (4.61) ANOVA table for HV for transformer oil.

Model 4 2523.90 630.97 139.87 0.000
Linear 4 2523.90 630.97 139.87 0.000
Ton 2 178.54 89.27 19.79 0.008
Ip 2 2345.36 1172.68 259.95 0.000
Error 4 18.04 4.51
Total 8 2541.94
Table (4.62) ANOVA table for HV for gas oil.

Model 4 4247.14 1061.78 59.06 0.001
Linear 4 4247.14 1061.78 59.06 0.001
Ton 2 210.06 105.03 5.84 0.065
Ip 2 4037.08 2018.54 112.27 0.000
Error 4 71.92 17.98
Total 8 4319.06
- 132 -
Table (4.63) ANOVA table for HV for kerosene.

Model 4 2536.66 634.16 91.71 0.000
Linear 4 2536.66 634.16 91.74 0.000
Ton 2 113.03 56.51 8.18 0.039
Ip 2 2423.63 1211.81 175.30 0.000
Error 4 27.65 6.91
Total 8 2564.31
Table (4.64) ANOVA table for HV for vegetable oil.

Model 4 5733.79 1433.45 132.93 0.000
Linear 4 5733.79 1433.45 132.93 0.000
Ton 2 475.62 237.81 22.05 0.007
Ip 2 5258.17 2629.08 243.81 0.000
Error 4 43.13 10.78
Total 8 5776.92
4.9.5.b. Determining Degree of Regression Model for HV

These coefficients were used to develop the mathematical model. The
mathematical relation between input parameters and HV for correlating HV has
- 133 -
been obtained in regression equations for transformer oil, gas oil, kerosene,
vegetable oil, as shown in equations of [(4.17), (4.18), (4.19), and (4.20)].
HV1 = 202.944 - 5.04 Ton (50) - 0.74 Ton (100) + 5.79 Ton (200) - 20.91 IP (10)
+ 2.52 IP (24) + 18.39 IP (50) …………. (4.17)
HV2 = 188.78 - 6.31 Ton (50) + 0.89 Ton (100) + 5.42 Ton (200) - 28.24 IP (10)
+ 5.49 IP (24) + 22.76 IP (50) …………. (4.18)
HV3 = 193.889 - 4.06 Ton (50) - 0.52 Ton (100) + 4.58 Ton (200) - 21.22 IP (10)
+ 2.48 IP (24) + 18.74 IP (50) ………..... (4.19)
HV4 = 205.70 - 7.80 Ton (50) - 1.90 Ton (100) + 9.70 Ton (200) - 31.33 IP (10)
+ 3.83 IP (24) + 27.50 IP (50) ………….. (4.20)

Model Summary displays the statistics that compares how well different
tables [(4.65)-(4.68)].
- 134 -
Table (4.65) Model summary for HV for transformer oil.

2.12394 99.24% 98.58% 96.41%
Table (4.66) Model summary for HV for gas oil.

4.24022 98.33% 96.67% 91.57%
Table (4.67) Model summary for HV for kerosene.
2.62922 98.92% 97.84% 94.54%
Table (4.68) Model summary for HV for vegetable oil.
3.28380 99.25% 98.51% 96.22%
- 135 -
Chapter Five Conclusions and Recommendations
5.1 Introduction
This study has tackled the effects of machining parameters on the

machining responses in the EDM process. The experiments were conducted
with various parameters setting such as pulse on time (Ton), the current (Ip) and
dielectric on machining outputs such as (MRR, EWR, SR, WLT, and HV). The
results obtained from experiments, were discussed and analyzed by intelligence
systems. Minitab 17 software was used to develop mathematical models for
prediction of the results.
5.2 Conclusions
Based on the study findings, the following conclusions can be drawn:
1. The MRR of ASTM stainless steel 316L for vegetable oil, transformer oil
and gas oil as dielectric resulted in 163%, 52% and 5% higher MRR,
respectively, than kerosene at higher Ton (200 µs) and higher value of IP
(50 A).
2. Vegetable oil showed lower EWR than others dielectrics, the average
relative performance of vegetable oil, kerosene and gas oil resulted in
48%, 30% and 26% lower EWR than transformer oil at higher Ton (200
µs) and higher value of IP (50 A).
3. The SR in vegetable oil, transformer oil, gas oil produced 47%, 27%, and
9% lower SR, respectively than kerosene at higher Ton (200 µs) and higher
value of IP (50 A).
4. The white layer thickness is thin for kerosene than vegetable oil, the
average relative performance of kerosene gas oil and transformer oil
resulted in approximately 62%, 28% and 14% lower WLT, respectively,
- 136 -
compared to vegetable oil at higher Ton (200 µs) and higher value of IP (50
A).
5. The micro-hardness is greater for vegetable oil than others dielectrics due
to the high cooling rate is the reason for the hardness increase of the white
layer when machining performed in vegetable oil.
6. The average relative performance of vegetable oil, transformer oil, and
gas oil resulted in 11%, 2% and 0.5% higher HV, respectively, than
kerosene at higher Ton (200 µs) and higher value of IP (50 A).
7. When increasing the pulse-on-time and current, the material removal rate,
surface roughness, white layer thickness and micro-hardness are
increased.
8. Higher pulse-on-time exhibited lower EWR, however, reverse effect has
been observed with higher values of current.
9. Vegetable oil emanate lesser smoke and fewer odours and use of vegetable
oil as dielectric increase the productivity. In addition, the environmental
hazard of vegetable oil are lower.
10.From the software, the results revealed that the Factorial model can predict
the machining responses with a good accuracy of (R-sq=97.42 %) for
MRR at transformer oil, (R-sq = 98.82 %) for EWR at transformer oil, (R-
sq = 97.80%) for SR at kerosene, (R-sq =99.73%) for WLT at vegetable
oil, and (R-sq = 99.25 %) for HV at vegetable oil.
- 137 -
5.3 Recommendations for future work
1. Using other materials containing high carbon to study the effect of

different dielectrics on heat effect zone.
2. Studying the improvement of electric discharge machining (EDM)
performance with adding graphite powder to dielectric.
3. Studying the effect of other parameters on EDM process such as
(voltage, tool material, tool shape, polarity, etc.) on machining responses.
4. Studying the influence of dielectric characteristics such as (oxidability,
electrical conductivity, viscosity, etc.) on the EDM of any alloy.
5. Studying the influence of electro discharge polarity on the surface
integrity.
- 138 -
Haneen Lateef Abdulwahhab. Study the effect of different dielectric fluid on
surface integrity for electrical discharge machining (EDM). University of
Technology/ Department of Production Engineering and Metallurgy. M.SC.
Supervised: Asst. prof. Dr. Shukry Hammed Aghdeab 2019, 182
Abstract
This thesis aims to investigate the effect of using different dielectric liquids
including transformer oil, gas oil, kerosene and vegetable oil (sunflower) on the
material removal rate (MRR), electrode wear ratio (EWR), surface roughness
(SR), white layer thickness (WLT), and micro-hardness (HV) in EDM. Pulse-
and current of (10, 24, 50) A have been chosen as on-time of (50, 100, 200) µs
input parameters. Machining was carried out on stainless steel AISI 316L
specimens with a copper electrode. The factorial design was used to develop
mathematical models for each dielectric fluid to create plots to determine the
(MRR, EWR, SR, WLT and HV) performance with increasing pulse-on-time
(T on ) and current(I p ). The results show that the vegetable oil can be used as
lower EWR, best SR and high HV ،dielectric in EDM, it gives highest MRR
when compared to transformer oil, gas oil, and kerosene. Analysis of variance
results indicate that the pulse-on-time and current are the most important factors.
The MRR in vegetable oil, transformer oil, gas oil produced 163%, 52%, and
5% higher MRR, respectively, than kerosene and MRR increases with increase
in T on and I P . The EWR in vegetable oil, kerosene, gas oil resulted in 48%, 30%,
R R R R
and 26% lower EWR than transformer oil, EWR decreases with increase in T on R
R but increases with increase in I P . The SR in vegetable oil, transformer oil, gas oil
R R
produced 47%, 27%, and 9% lower SR, respectively than kerosene. In addition,
The WLT in kerosene, gas oil and transformer oil resulted in approximately
62%, 28% and 14% lower WLT, respectively, compared to vegetable oil. The
HV in vegetable oil, transformer oil, and gas oil resulted in 11%, 2% and 0.5%
higher HV, respectively, than kerosene. The SR, WLT, and HV increases with
increasing T on and I P .
Keywords: Electrical Discharge Machining: Material Removal Rate: Surface

Roughness: White Layer Thickness: Micro-Hardness: Pulse-On-Time: Current
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CHAPTER TWO
INTRODUCTION AND
LITERATURE SURVEY
CHAPTER ONE
PRINCIPLES OF EDM
CHAPTER THREE
EXPERIMENTAL WORK
CHAPTER FOUR
RESULTS AND
DISCUSSION
CHAPTER FIVE
CONCLUSIONS AND
RECOMMENDATIONS
FOR FUTURE WORK
REFERENCES
‫المستخلص‬
‫يهدف هذا البحث الى دراسة تاثير استخدام سوائل عازلة مختلفة بما في ذلك زيت المحوالت‪,‬‬
‫زيت الكاز‪ ,‬الكيروسين‪ ,‬و الزيت النباتي على معدل ازالة المادة )‪ ,(MRR‬معدل بلى القطب )‪,(EWR‬‬
‫الخشونة السطحية (‪ ,(SR‬وسمك الطبقة البيضاء (‪ ,(WLT‬والصالدة )‪ (HV‬في ‪. EDM‬زمن النبضة‬
‫ذو القيمة (‪ )055 ,055 ,05‬مايكروثانية والتيار (‪ )05 , 02 ,05‬أمبير تم اختياره كمدخالت ‪ ,‬تم تنفيذ‬
‫التشغيل على الفوالذ المقاوم للصدأ ‪ AISI 603L‬مع قطب النحاس‪ .‬تم استخدام التصميم فاكتوريال‬
‫لتطوير موديالت رياضية لكل عازل من اجل انشاء مخططات لتحديد كيفية أداء (‪SR ,EWR , MRR‬‬
‫‪ WLT ,‬و‪ )HV‬مع زيادة زمن النبضة والتيار‪ .‬أظهرت النتائج ان الزيت النباتي يمكن استخدامه كعازل‬
‫في ‪, EDM‬فهو يعطي أعلى ‪, MRR‬واقل ‪ , EWR‬افضل ‪ , SR‬واعلى‪ HV‬بالمقارنة مع زيت‬
‫المحوالت‪ ,‬زيت الكاز‪ ,‬والكيروسين‪ .‬واظهرت نتائج تحليل التباين الى ان التيار وزمن النبضه هما اهم‬
‫العوامل المؤثره على ‪ .HV ,WLT ,SR ,EWR ,MRR‬معدل ازاله المادة )‪ (MRR‬في الزيت‬
‫النباتي‪ ,‬زيت المحوالت‪ ,‬زيت الكاز تنتج ‪ %0 ,%00 ,%036‬اعلى ‪ ,MRR‬على التوالي مقارنة‬
‫بالكيروسين و ‪ MRR‬تزداد عند زيادة ‪ Ton‬و ‪ .IP‬معدل البلى للقطب في الزيت النباتي‪ ,‬الكيروسين‪ ,‬الكاز‬
‫ينتج بنسبة ‪ %03 ,%65 , %24‬اقل ‪ EWR‬مقارنة بزيت المحوالت‪ ,‬تقل ‪EWR‬عند زيادة ‪ Ton‬ولكن‬
‫تزداد مع زيادة ‪. IP‬الخشونة السطحية في الزيت النباتي ‪ ,‬زيت محوالت‪ ,‬زيت الكاز تنتج ‪,%04, %24‬‬
‫‪ %9‬اقل ‪ SR‬على توالي‪ ,‬مقارنة بالكيروسين‪ .‬بينما الكيروسين‪ ,‬زيت الكاز‪ ,‬زيت المحوالت ينتج تقريبآ‬
‫‪ %02 ,%04 ,%30‬اقل ‪ WLT‬على التوالي مقارنة بالزيت النباتي‪ .‬معدل االداء النسبي لزيت النباتي‬
‫‪,‬زيت المحوالت ‪ ,‬زيت الكاز ينتج ‪ %5.0 ,%0 ,%00‬اعلى ‪ HV‬على التوالي مقارنة بالكيروسين‪.‬‬
‫‪. IP‬‬ ‫ال ‪WLT, ,SR‬و ‪ HV‬تزداد مع زيادة كل من ‪Ton‬و‬
‫جمهورية العراق‬
‫وزارة التعليم العالي والبحث العلمي‬
‫الجامعة التكنولوجية‬
‫قسم هندسة اإلنتاج والمعادن‬
‫دراسة تأثير اختالف السائل العازل على تكامل‬

‫السطح بماكنة الشرارة الكهربائية‬
‫رسالة مقدمة إلى قسم هندسة اإلنتاج والمعادن في الجامعة التكنولوجية وهي جزءا‬
‫من متطلبات نيل درجة الماجستير في علوم هندسة اإلنتاج‬
‫قد َمتها‬
‫حنين لطيف عبدالوهاب‬
‫بإشراف‬
‫أ‪.‬م ‪.‬د‪ .‬شكري حميد غضيّب‬
‫‪ 2019‬ميالدي‬ ‫‪ 1440‬هجري‬

Effect of Dielectric Fluids on Surface Integrity in EDM

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Republic of Iraq

Ministry of Higher Education and Scientific Research

Study the effect of different dielectric fluid on

2019 A.D. 1440 A.H.

‫آمَ نواِإِذَاِقِ ي ِلَِلَكِ ِْمِتَفَ ِسَّحِ واِِِِِِ‬ ‫﴿ِيَاِأَيِ َهاِالَّ ِذ َِ‬

‫فِيِا ْلمَ ِجَ الِ ِِ‬

‫يلَِانشِ زواِف انشِزواِيَ ْرفَِِعِاللَّهِِالَّ ِذي َِ‬

‫ينِأوتواِا ْلعِْل ِمَِدَ َرجَاتِِ َواللَّهِِبِمَا‬

I dedicate this thesis

To lovely parents, my brother and close

To all persons who have supported me and

encouraged me to complete this work

First of all, thanks to God for enabling me to complete this work.

Chapter one: principles of EDM

1.1 Introduction of EDM 1

1.2 Principles of EDM process 3

1.3 Mechanism of EDM Process 5

1.4 EDM process parameters 8

1.4.1 Input parameters 8

1.4.1.a Pulse on time (Ton) 8

1.4.1.b Pulse off time (Toff) 9

1.4.1.e Dielectric fluid 10

1.4.2 Response or performance parameters 11

1.4.2.a Material Removal Rate (MRR) 11

1.4.2.b Electrode wear (EW) 11

1.4.2.c Surface Roughness (SR) 13

1.4.2.d The surface layer 14

1.5 Properties of dielectric fluids that need to be considered while 15

1.6 Functions of the Dielectric 16

1.7 Requirements of Dielectric Fluid 17

1.8 Advantages of EDM 17

1.9 Limitation of EDM 18

1.10 Applications of EDM 19

Chapter Two: Introduction and Literature Survey

2.2 Summery of literature survey 32

Chapter Three: Experimental Work

3.3 The dielectric fluid 38

3.4 The workpiece material 38

3.5 The electrode tool material 41

3.6 Selection of the machining parameters 43

3.7 Experimental design 45

3.8 Experimental procedure 45

3.9 Measurement of responses 47

3.9.1 Measurement of material removal rate (MRR) and electrode 47

3.9.2 Measurement of surface roughness (SR) 48

3.9.3 Measurement of White Layer Thickness (WLT) 49

3.9.4 Measurements Micro hardness (HV) 52

Chapter Four: Results and discussion

4.2 Design of experimental (DOE) 54

4.3 The Experimental Results 55

4.4 Dielectric transformer oil 64

4.4.1 Effect of pulse-on-time and current on MRR 64

4.4.3 Effect of pulse-on-time and current on SR 66

4.4.4 Effect of pulse-on-time and current on WLT 67

4.4.5 Effect of pulse-on-time and current on HV 68

4.5 Dielectric gas oil 69

4.5.1 Effect of pulse-on-time and current on MRR 69

4.5.2 Effect of pulse-on-time and current on EWR 70

4.5.3 Effect of pulse-on-time and current on SR 70

4.5.4 Effect of pulse-on-time and current on WLT 71

4.5.5 Effect of pulse-on-time and current on HV 72

4.6 Dielectric kerosene 73