Restricted accessResearch articleFirst published online 2026
Experimental investigation of the effects of type and concentration of ionic liquids added to kerosene as dielectric fluid on the performance of the magnetic field-assisted EDM process
The disadvantages of electrical discharge machining (EDM) are low metal removal rate (MRR), high tool wear rate (TWR) and surface roughness (SR), and formation of cracks and recast layer on machined surfaces. In this study, magnetic field-assisted EDM (MEDM) with a mixture of kerosene and different volumes of three types of biodegradable ionic liquids, as dielectric fluid, was used to machine AISI H13 hot work steel and decrease the EDM process limitations. So the effects of volume percent of different ionic liquids (monoethanolamine formate (MEA-Formate), diethanolamine acetate (DEA-Acetate), and triethanolamine lactate (TEA-Lactate)) added to kerosene, on MRR, TWR, SR, recast layer thickness, and distribution of generated cracks on the machined surface were studied at different discharge energies. The results showed that adding 1% and 3% by volume of each of the ionic liquids to kerosene as dielectric fluid increases the MRR and decreases the TWR, SR, recast layer thickness, and the distribution of generated cracks on the machined surface, at different discharge energies, in the MEDM process. The greatest increase in MRR and decrease in TWR is related to using 3% by volume of MEA-Formate ionic liquid. The greatest decrease in SR is related to using 1% by volume of MEA-Formate ionic liquid.
HoKHNewmanST. State of the art electrical discharge machining (EDM). Int J Mach Tools Manuf2003; 43: 1287–1300.
2.
ShabgardMROliaei, S.NBSeyedzavvarM, et al.Experimental investigation and 3D finite element prediction of the recast layer thickness, heat affected zone, and surface roughness in EDM process. J Mech Sci Technol2011; 25: 1–11.
3.
ZabihiSSSoleimanimehrHEtemadi HaghighiS, et al.Effects of variable magnetic field assisted EDM on MRR and surface integrity of AZ80 magnesium. Mater Manuf Processes2023; 38: 836–847.
4.
FarooqMUBhattiHAAsadM, et al.Surface generation on titanium alloy through powder-mixed electric discharge machining with the focus on bioimplant applications. Int J Adv Manuf Technol2022; 122: 1395–1411.
5.
WuKLYanBHLeeJW, et al.Study on the characteristics of electrical discharge machining using dielectric with surfactant. J Mater Process Technol2009; 209: 3783–3789.
6.
WuKLYanBHLeeJW, et al.Study on the characteristics of electrical discharge machining using dielectric with surfactant. J. Mater. Process. Technol2009; 209: 3783–3789.
7.
KhanSAOmerMFarooqMU, et al.Effect of powder particle concentration, pulse duration, and pulse current on machined surface characterization produced via EDM of biocompatible WE-43Mg alloy. Scientific Reports volume 152025; Article number: 33927.
8.
KhanAAAl HazzaMHF. Performance of electrical discharge machining (EDM) with nickel added fluid. IIUM Engineering Journal2018; 19: 45–59.
9.
GunawanSSrianiTMahardikaM, et al.Application of powder suspended in dielectric fluid for fine finish micro-EDM of inconel 718. Int J Adv Manuf Technol2014; 72: 2269–2281.
10.
TallaGGangopadhyaySBiswasCK. Effect of powder-suspended dielectric on the EDM characteristics of inconel 625. Particulate Science and Technology, Journal of Materials Engineering and Performance2015; 24: 2787–2797.
11.
JahanMPRahmanMWongYS. Study on the nano-powder-mixed sinking and millingmicro-EDM of WC-co. Int J Adv Manuf Technol2011; 53: 167–180.
12.
MughalMFarooqMMumtazJ, et al.Surface modification for osseointegration of Ti6Al4 V ELI using powder mixed sinking EDM. J Mech Behav Biomed Mater2021; 113: 104–145.
13.
LeeVT. The influence of additive powder on machinability and surface integrity of SKD61 steel by EDM process. Mater Manuf Processes2021; 36: 1084–1098.
14.
LinY-CLeeH-S. Machining characteristics of magnetic force-assisted EDM. Int J Mach Tools ManufSeptember 2008; Volume 48: Pages 1179–1186.
15.
BainsPSSidhuSSPayalHS. Magnetic field assisted EDM: new horizons for improved surface properties. Silicon2018; Volume 10: pages 1275–1282.
16.
JoshiSGovindanPMalsheA, et al.Experimental characterization of dry EDM performed in a pulsating magnetic field. CIRP Ann2011; Volume 60: Pages 239–242.
17.
GholipoorABaseriHShakeriM, et al.Investigation of the effects of magnetic field on near-dry electrical discharge machining performance. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture2016; 230: 744–751.
18.
LinYCChenYFWangDA, et al.Optimization of machining parameters in magnetic force assisted EDM based on taguchi method. J Mater Process Technol2009; 209: 3374–3383.
19.
ShabgardMRGholipoorAMohammadpourfardM. Investigating the effects of external magnetic field on machining characteristics of electrical discharge machining process, numerically and experimentally. The International Journal of Advanced Manufacturing Technology2019; 102: 55–65.
20.
HossainMMAb KarimMSBHoongWY, et al.Feasibility of Using CeO2/Water Dielectrical Nanofluid in Electrical Discharge Machining (EDM). Arab J Sci Eng2020; 45: –9.
21.
FarooqMUTlijaMAliS, et al.Application of non ionic liquids based modified dielectrics during electric discharge machining (EDM) of Ti6Al4 V alloy to enhance machining efficiency and process optimization. Sci Rep2024; 14: –8.
22.
KadimiAKaddamiHOunaiesZ, et al.Preparation and dielectric properties of poly (acrylonitrileco- 2,2,2 trifluoroethyl methacrylate) materialsviaradical emulsion copolymerization. Polym. Chem2019; 10: 5507–5521. doi:10.1039/C9PY00673G.
23.
WangBJiRGongZ, et al.Effect of water in oil emulsion on the surface quality of inconel 718 alloy during coupling electrical pulse and ultrasonic treatment. Surf. Coat. Technol2022; 437: 128355.
24.
LiuYJiRZhangY, et al.Investigation of emulsion for die sinking EDM. Int. J. Adv. Des. Manuf. Technol2010; 47: 403–409. 6Y.
25.
ZhangYLiuYJiR, et al.Sinking EDM in water-in-oil emulsion. Int. J. Adv. Des. Manuf. Technol2012; 65: 705–716.
26.
ZhangYLiuYShenY, et al.Investigation on the influence of the dielectrics on the material removal characteristics of EDM. J. Mater. Process. Technol2014; 214: 1052–1061.
27.
DongHLiuYLiM, et al.Sustainable electrical discharge machining using water in oil nanoemulsion. J. Manuf. Processes2019; 46: 118–128.
28.
FarooqMUTlijaMAliS, et al.Adediran; application of non-ionic liquids-based modified dielectrics during electric discharge machining (EDM) of Ti6Al4 V alloy to enhance machining efficiency and process optimization. Sci Rep2024; 14: 20797.
29.
NasirpourNMohammadpourfardMZeinali HerisS. Ionic liquids: promising compounds for sustainable chemical processes and applications. Chem Eng Res Des2020; 160: 264–300.
30.
ZhouQ. Physicochemical properties of ionic liquids. In: Ionic liquids further UnCOILed. First Edition. USA: Critical Expert Overviews, 2014, pp.15–30.
31.
PlechkovaNVSeddonKR. Applications of ionic liquids in the chemical industry. The Royal Society of Chemistry2007; 3: 243–268.
32.
MacFarlaneDRTachikawaNForsythM, et al.Energy applications of ionic liquids. The Royal Society of Chemistry2014; 7: 183–212.
33.
Van RantwijkFSheldonRA. Biocatalysis in ionic liquids. Chem Rev2007; 107: 2585–2614.
34.
ShabgardMRGholipoorAMohammadpourfardM. Numerical and experimental study of the effects of ultrasonic vibrations of tool on machining characteristics of EDM process. The International Journal of Advanced Manufacturing Technology2018; 96: 2657–2669.
35.
ShabgardMRGholipoorAMohammadpourfardM. A novel approach to plasma channel radius determination and numerical modeling of electrical discharge machining process. Journal of the Brazilian Society of Mechanical Sciences and Engineering2020; 42.
36.
GostimirovicMKovacPSekulicM, et al.Influence of discharge energy on machining characteristics in EDM. J Mech Sci Technol2012; Volume 26: pages 173–179.
37.
KimC-HKruthJP. Influence of the electrical conductivity of dielectric on WEDM of sintered carbide. J Mech Sci Technol2001; Volume 15: pages 1676–1682.
38.
LiuQZhangQZhangM, et al.Study on the discharge characteristics of single-pulse discharge in micro-EDM. Micromachines (Basel)2020; 11: 55.
39.
KimC-HKruthJP. Influence of the electrical conductivity of dielectric on WEDM of sintered carbide. KSME Int J2001; 15: 1676–1682.
40.
MujumdarSSCurreliDKapoorSG. Effect of dielectric electrical conductivity on the characteristics of micro electro-discharge machining plasma and material removal. Journal of Micro and Nano Science and Engineering2016; 4: 021006 (9 pages).
41.
PriyankaPJayakumarVGiridharanPK, et al.Sustainable machining and optimization of machining parameters utilizing different dielectrics in EDM machining of waspaloy. Sci Rep2025; volume 15: Article number: 33241.
42.
LeVT. The role of electrical parameters in adding powder influences the surface properties of SKD61 steel in EDM process. J Brazilian Soc Mech Sci Eng2021; 43: 120.
43.
MandalKSekhMBoseD, et al.Influence of dielectric conductivity on corner error in wire electrical discharge machining of Al 7075 alloy. Proc Inst Mech Eng Part C: J Mech Eng2020; 235. DOI: 10.1177/09544062209782
44.
YeoSHKurniaWTanPC. Electro-thermal modeling of anode and cathode in micro-EDM. J Phys D Appl Phys2007; 40: 2513–2521.
45.
MohammadrezaSOliaei SamadNBMirsadeghS, et al.Experimental investigation and 3D finite element prediction of the white layer thickness, heat affected zone, and surface roughness in EDM process. J Mech Sci Technol2011; 25: 1–11.
46.
RajurkarKPZhangB. The electrical discharge machining (EDM) handbook. Mach Sci Technol Int J2007; 3: 141–142.
47.
KumarDDikshitMKChaudharyN, et al.Selection of nano powder mixed dielectric fluid (NPMDF) in electric discharge machining using hybrid multi-criteria decision-making method. Discover Applied Sciences2025; Volume 7: article number 75.
48.
Van-TaoLDang VanTCuongPH. Investigation and optimization of machining peculiarities of heat treatment and non-heat treatment X40CrMoV51 alloy by powder-suspended electro-discharge machining in final-finishing operation. Proc Inst Mech Eng Part C: J Mech Eng2025; 239: 7869–7887. 10.1177/09544062251350471
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
