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Hydrocarbon-based flushing media have proved their superiority as a flushing media for EDM process in terms of performance characteristics, but serious health issues such as skin cancer, respiratory problems, and lung cancer are predominant among the operators. An experimental investigation was conducted to study the feasibility of the biodiesels as a flushing media during µED Milling of Inconel 718 alloy with WC tool under three different discharge energy range. The behavior of biodiesel is the same as EDM oil, but the EDM oil have a higher metal removal rate and minimum roughness compared to biodiesel. Palm biodiesel was in close proximity range with EDM oil than jatropha and karanja biodiesels in terms of response measures. The breakdown voltage of biodiesels was found to be higher than EDM oil. Crater diameter increased by 16%, 22%, and 31%, respectively, with palm, jatropha, and karanja biodiesel fluids than EDM oil. Biodiesel could be a real alternative to hydrocarbon oil for µED milling in terms of performance and safer environment. Minimum hardness was achieved when the biodiesels were used as the flushing media at considered discharge energy range due to lesser carbon deposition. MRR was decreased by 55% with palm biodiesels as compared to EDM oil dielectric fluid. Microhardness was increased by 10% with EDM oil as compared to Karanja biodiesel under considered discharge energy.

Performance comparison of EDM oil and biodiesel flushing media while µED milling of Inconel 718