Development of CO2 efficiency index for evaluating sustainability of microelectrical discharge drilling process

Abstract

Recently, there has been a growing awareness of environmental issues, and the concept of sustainability has been introduced. This concept applies to different fields, including the manufacturing industry. This study focuses on the sustainability of the micro-electrical discharge machining (EDM) drilling process. In EDM technology, the critical aspects of sustainability are consumed energy, electrode wear, gas emissions, and generated waste. The operational conditions impact consumption and emissions. The aim of this study is to develop a CO2 efficiency index for evaluating the environmental–economic efficiency of the micro-EDM drilling process. The index was calculated as the emissions that occurred during machining and logistic activities divided by the added value, and it was expressed as the kg equivalent CO2 per unit money. For the emissions, all process activities that have an environmental impact were considered, such as transportation, absorbed energy generation, production of fumes by the dielectric during machining, and emissions attributed to the production of nonconforming pieces. The proposed index was applied to a medical case study in which titanium bone plates were produced for fractures of small body parts. It was found that the process performance significantly depended on the operation conditions of the dielectric fluid and electrode. The material removal rate (MRR) significantly influenced the index. Quality problems and scraping influenced the overall performance significantly, whereas dielectric management had a moderate effect. The optimum conditions were determined by varying the dielectric fluid, electrode material, and process parameters. Demineralized water was the best dielectric because it facilitated a high MRR, whereas hydrocarbon oil resulted in a high quality and a low scrap rate. Vegetable oil caused problems, resulting in a low MRR and poor quality. Further investigations should be conducted to improve its performance in microdrilling applications.