ABSTRACT The alternative dielectrics like vegetable oils, emulsions, and different organic solutions have captured the emerging research attentions, and few pieces of literature also discussed about their potentiality to replace conventional kerosene. However, observations of the existing literatures are limited up to the assessment of the primary responses like material removal rate (MRR), surface roughness (SR), hardness, etc., which are not sufficient to recommend them as a suitable one. Therefore, the present work intends to incorporate a little bit value-addition to the existing research by including their impacts on the crater-overlapping, debris-agglomeration, surface integrity, and recast-layer thickness of the EDM-surface. Here, the machining is performed on the titanium alloy ‘Ti6Al4V’ using a cylindrical copper tool with various flushing pressures, and the obtained outcomes are compared with that of conventional kerosene. Findings claim the presence of spikes, black spots, and discrete thermal defects with comparatively thinner recast thickness when bio-dielectric was used. Moreover, comparatively 20.75% higher MRR, 16.68% less SR, and 18.75% more tool wear rate (TWR) are noticed for bio-dielectric within the permissible range of the flushing pressure, but beyond this range, 4–6.5% reduction in MRR and 26.00–31.5% increment in TWR are observed.

中文翻译：

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评估生物电介质对 EDM 表面的纹理特征和重铸层的影响

摘要 植物油、乳液和不同有机溶液等替代电介质引起了新兴的研究关注，很少有文献讨论它们替代传统煤油的潜力。然而，对现有文献的观察仅限于对材料去除率 (MRR)、表面粗糙度 (SR)、硬度等主要响应的评估，这些不足以推荐它们作为合适的响应。因此，目前的工作旨在通过包括它们对 EDM 表面的陨石坑重叠、碎片聚集、表面完整性和重铸层厚度的影响，为现有研究增加一点价值。这里，使用圆柱形铜刀具在各种冲洗压力下对钛合金“Ti6Al4V”进行加工，并将获得的结果与传统煤油的结果进行比较。结果表明，当使用生物电介质时，存在尖峰、黑点和离散热缺陷，重铸厚度相对较薄。此外，在允许的冲洗压力范围内，生物电介质的 MRR 提高了 20.75%，SR 降低了 16.68%，工具磨损率 (TWR) 提高了 18.75%，但超出这个范围，MRR 降低了 4-6.5%观察到 TWR 增加了 26.00-31.5%。当使用生物电介质时，重铸厚度相对较薄的离散热缺陷。此外，在允许的冲洗压力范围内，生物电介质的 MRR 提高了 20.75%，SR 降低了 16.68%，工具磨损率 (TWR) 提高了 18.75%，但超出这个范围，MRR 降低了 4-6.5%观察到 TWR 增加了 26.00-31.5%。当使用生物电介质时，重铸厚度相对较薄的离散热缺陷。此外，在允许的冲洗压力范围内，生物电介质的 MRR 提高了 20.75%，SR 降低了 16.68%，工具磨损率 (TWR) 提高了 18.75%，但超出这个范围，MRR 降低了 4-6.5%观察到 TWR 增加了 26.00-31.5%。