This research work explores the use of vegetable oil-based dielectrics in Electrical Discharge Machining (EDM). For the promotion of sustainable machining viscous nature of pure Jatropha oil (PJO) hinders its direct application as a dielectric in sustainable EDM. The concept of Binary Blending Mechanism (BBM) is employed to for mitigation of this issue by mixing PJO with various oils (coconut, groundnut, sunflower, and EDM) across five different volume proportions. The impact of these blends on dielectric properties, including density, flash point, electrical conductivity, and breakdown voltage, was evaluated for their machining potential. The PJO-coconut oil combination proved most effective, demonstrating a significant reduction in viscosity (45.5%) and BDV (22.9%), increase in density (1.09%), flash point (10%), electrical conductivity (0.91%). A supervised machine learning decision tree model has been developed and trained on 20 data points for the prediction of the optimal blend composition providing a data-driven approach to achieve sustainable and efficient EDM.
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