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Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Investigating Feasibility Through Performance


Analysis of Green Dielectrics for Sustainable
Electric Discharge Machining

Janak B. Valaki & Pravin P. Rathod

To cite this article: Janak B. Valaki & Pravin P. Rathod (2016) Investigating Feasibility Through
Performance Analysis of Green Dielectrics for Sustainable Electric Discharge Machining, Materials
and Manufacturing Processes, 31:4, 541-549, DOI: 10.1080/10426914.2015.1070430

To link to this article: https://doi.org/10.1080/10426914.2015.1070430

Accepted author version posted online: 24


Jul 2015.
Published online: 11 Nov 2015.

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Materials and Manufacturing Processes, 31: 541–549, 2016
Copyright # Taylor & Francis Group, LLC
ISSN: 1042-6914 print=1532-2475 online
DOI: 10.1080/10426914.2015.1070430

Investigating Feasibility Through Performance Analysis of Green


Dielectrics for Sustainable Electric Discharge Machining
Janak B. Valaki1,2 and Pravin P. Rathod3
1
School of Engineering, RK University, Rajkot, Gujarat, India
2
Mechanical Engineering Department, Government Engineering College, Bhavnagar, Gujarat, India
3
Mechanical Engineering Department, Government Engineering College, Bhuj, Kuttchh, Gujarat, India

This work represents a feasibility study for the newly proposed vegetable oil-based green dielectric fluids, biodielectric1 (BD1) and
biodielectric2 (BD2) for electric discharge machining (EDM). Comparative analyses for BD1, BD2, and kerosene have been studied to assess
the performance in terms of material removal rate (MRR), electrode wear rate (EWR), and relative wear ratio (RWR) for
P20 þ cold-worked plastic injection mold steel using electrolytic grade copper electrode. Current, gap voltage, pulse on time (Ton), and pulse
off time (Toff) have been chosen as input parameters, and one variable at a time approach has been used for designing experimental plan for
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investigating the feasibility of the newly suggested fluids. The results obtained show that the performance of the newly suggested biodielec-
trics BD1 and BD2 is better than commercially used hydrocarbon-based dielectric, i.e., kerosene, for MRR and RWR. Analysis of variance
results indicated that current is the most influencing parameter for MRR and EWR, while Ton is the most significant parameter for RWR.
Under the influence of current, BD1 and BD2 produced 38% and 165% improvement in MRR, respectively. Moreover, BD1 and BD2
resulted 30% higher and 7% lower RWR, respectively, under the influence of Ton.

Keywords Biodielectrics; EDM; EWR; Manufacturing; MRR; RWR; Sustainability; Vegetable oil.

INTRODUCTION and adversely affect operator health and safety [4–9].


Electric discharge machining (EDM) is the most Leao and Pashby [4] have also reported that the dielec-
widely practiced nonconventional material removal pro- tric fluid plays important functions regarding pro-
cess and fourth amongst all material removal processes ductivity, costs, and quality of the machined parts.
after milling, turning, and grinding [1]. EDM process The electrical, mechanical, and thermal properties of
employs high-frequency discrete electric sparks to cause the dielectric fluid influence the processes of discharge
thermoelectric decomposition of the dielectric fluid, initiation, plasma expansion, material erosion, debris
which generates intense amount of heat in the order of removal, and discharge channel reconditioning in
8000–12,000 K, resulting in a rapid melting and vapori- EDM [10]. Evertz et al. [11] have investigated that type
zation of the work material [2]. Discrete and controlled of dielectric fluid and its supply mode are significant to
electric sparks generate dimensionally and geometrically have stable, efficient, and operator-friendly material
accurate profiles on materials of any hardness. Hence, removal process. Valaki et al. [12] have categorized the
EDM is the preferable metal removal process for the functions performed by dielectric fluids in EDM process
manufacture of tools, molds, and dies; surface texturing as primary and secondary functions. These functions act
of steel rolls; surface alloying; production of compo- as a basis for selection of desired properties of dielectric
nents for aero engines, electronics, surgical industries; fluids and compare various dielectrics.
and manufacture of metallic prosthesis [3, 4]. Researchers have experimented using alternate dielectrics
In EDM, dielectric fluid undergoes partial ionization with a view to improve process performance, better opera-
due to rapid rise and fall of the intense temperature tor’s safety, minimize fire hazards, and lessen environmental
and pressure during short spark cycles. Researchers have impact. Various types of fluids, such as water [13, 14] and
reported that dielectric fluids such as kerosene and min- water-based solutions [15, 16], chemical compounds, and
eral oil produce emissions like solid metallic particles, mixed water-based dielectrics [17], have been proposed
tiny droplets of liquid dielectric, emitted gases, and and experimented. Leao and Pashby [4] reported that water-
waste dielectric sludge that cause environment pollution and gas-based dielectrics need further investigations to make
it commercially viable alternates as dielectric. It has also
been reported that even though EDM with plain water
resulted in better performance under special conditions,
Received March 17, 2015; Accepted June 9, 2015
Address correspondence to Janak B. Valaki, Mechanical Engineer-
hydrocarbon oil-based dielectrics are superior in a broader
ing Department, Government Engineering College, Bhavnagar, range of machining conditions. Zhang et al. [9] and Liu
Gujarat 364001, India; E-mail: janakvalaki@gmail.com et al. [18] have proposed and reported that water-in-oil
Color versions of one or more of the figures in the article can be emulsions are superior to hydrocarbon oils when working
found online at www.tandfonline.com/lmmp. with high energy levels. Oil-in-water emulsions have been

541
542 J. B. VALAKI AND P. P. RATHOD

TABLE 1.—Electrode material composition.

Element Cu Ni Tin Zn Mn Al C Si Lead P Ar Su

Composition (%) 99.71 0.019 0.005 0.13 0.001 0.007 0.03 0.002 0.01 0.038 0.002 0.029

proposed by Liu et al. [19] with a view to improve environ- Transesterified form of selected vegetable oil-based
mental, health, and safety aspects of EDM process. biodielectric fluids (BD1 and BD2) and commercial
Vegetable plant-based natural oils possess dielectric grade kerosene were used as dielectric fluids for this
properties comparable to or even better than hydro- study. Transesterified form of BD1 and BD2 contain
carbon- and mineral oil-based dielectrics [20]. Many free fatty acids contents less than 1% and traces of other
researchers have experimented with natural oils as impurities are less than 1%. Properties of BD1, BD2,
dielectric fluid for power transformers and other electri- and kerosene dielectric fluids used are shown in Table 3.
cal engineering applications [21, 22]. There is an increas- The experiments were performed in die sinking EDM
ing trend toward using vegetable oil-based dielectric machine (Sparkonix India Pvt. Ltd., Pune, India), as
fluid due to its high sustainability index. Khan et al. shown in Fig. 1. The EDM machine was supported
[23] have reported that amongst all bio-oils, waste veg- by metal-oxide-semiconductor field-effect transistor
etable oil (WVO) has the highest impact index of sus- (MOSFET) controller, having a current rating of 25 A,
tainability. Moreover, it is cheapest of all bio-oils. as a pulse generator for the process.
Jatropha oil is nonedible and hence does not affect food An experimental setup was developed to supply dielec-
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chain sustainability. In our earlier study [24], we have tric fluid through a submerged type single-jet flushing
reported a qualitative assessment of suitability of veg- system, which includes a dielectric supply system with
etable oil-based bio-oils as dielectrics for EDM. a submersible pump. Current, gap voltage, pulse on time
Authors, in this research article, have proposed two veg- (Ton), and pulse off time (Toff) were used as input para-
etable oil-based biodielectric fluids, Jatropha oil (BD1) meters. In order to assess the performance of the sug-
and WVO (BD2), as green dielectrics for EDM process. gested biodielectrics, ranges of input parameters have
Experimental investigations have been performed to been selected to cover 20%–80% of the available range
evaluate the relative performance of the proposed biodi- on the machines, and within selected range, six intervals
electric fluids with kerosene to analyze material removal have been selected as shown in Table 4. Constant
rate (MRR) in mm3=min, electrode wear rate (EWR) in machining conditions used for the experiments are sta-
mm3=min, and relative wear ratio (RWR) of workpiece ted in Table 5. A total 24 sets of experiments, each hav-
and electrode materials in percentage (%). ing a cycle time of 10 minutes, were performed using one
variable at a time approach. Absolute weight difference
MATERIALS AND METHODS of the electrode and work materials were measured using
For this study, M238 HH grade (equivalent to 20 mg accuracy digital weighing scale. Absolute weight
P20 þ grade) cold-worked plastic mold steel samples were differences of workpiece and electrode materials were
used as workpiece material since it is widely being used divided by erosion cycle time and densities of the materi-
for plastic die and mold manufacturing using die sinking als to calculate of MRR and EWR. RWR was calcu-
process. Material was pre-hardened and tempered, lated taking the ratio of EWR=MRR. In order to
having a Brinell hardness number (BHN) of 355–359 and calculate the relative percentage difference for the
size of the sample as 100 mm  50 mm  15 mm (length  response parameters, average of the results of the six
breadth  thickness). 99.73% pure electrolytic grade cop- levels has been taken. A statistical tool, analysis of vari-
per rods of 20 mm diameter were used as electrodes for ance (ANOVA), has been used to sort out the significant
the experiments. Chemical compositions of the workpiece input variables for BD1, BD2, and kerosene. Moreover,
material and the electrode material is shown in Tables 1 percentage significance of each input variable on the
and 2, respectively. output responses has been calculated.

TABLE 2.—Workpiece material composition.

Element C Si Mn P S Cr Mo Ni Al

Composition (%) 0.36 0.28 1.52 0.008 0.001 1.88 0.22 0.95 0.021

TABLE 3.—Properties of biodielectrics BD1, BD2, and kerosene.

Density Viscosity at Thermal conductivity Specific heat Flash point BD voltage Dielectric
No. Dielectric (g=ml) (40 C) (W=m.K) (KJ=kg.K) ( C) (KV=2.5 mm) constant

1 Kerosene 0.80 2.71 0.15 2.01 81 18 4.7


2 BD1 0.8787 4.72 0.157 1.90 158 35.8 2.53
3 BD2 0.8932 9.55 0.20 1.67 171 26 2.86
GREEN DIELECTRICS FOR SUSTAINABLE ELECTRIC DISCHARGE MACHINING 543
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FIGURE 1.—EDM machine used for the experiment.

RESULTS AND DISCUSSION is eroded [15, 25, 26]. Moreover, higher current density
Performance analysis is mainly aimed to study and increases the temperature and pressure inside the plasma
analyze the relative performance of the proposed biodi- channel, which eventually increases the erosion of the
electrics, i.e., BD1 and BD2 with that of kerosene. work material [27]. For the same current values, BD2
Influence of control parameters, i.e., current, gap resulted in the highest MRR, followed by BD1 and
voltage, Ton, and Toff on MRR, EWR, and RWR has kerosene. The average relative performance of BD1
been stated as below. MRR is termed as machining time was 38% higher, while BD2 performed 165% better than
per unit volume of material removed, which is related to kerosene. The resulted higher MRR in the case of BD1
the production cost. Higher MRR is desirable for and BD2 is due to higher breakdown voltage and vis-
achieving more economical production. EWR is related cosity, which could have resulted into higher spark
to the amount of erosion and electrode material energy density [28]. Moreover, higher oxygen content
experience during the experiment. It is associated with of BD1 and BD2 [29] generated higher average tempera-
the tooling cost of the process. Hence, lower EWR is ture of plasma channel, which could have improved
desirable to justify the economic feasibility of the melting and evaporation of work material and hence
suggested biodielectrics. RWR is related to the relative MRR [13]. Also, higher oxygen content could have
material erosion rate of MRR and EWR. Lower RWR ensured better dispersion of discharge energy to increase
is preferable from a machining economics point of view. MRR [30].
Figure 2(a)–2(c) shows the actual pictures of the
workpiece samples produced during experiments and
used electrode samples are shown in Fig. 2(d).
Results in Fig. 3(a) show the comparative plots for TABLE 5.—Constant parameters and its values.
MRR under the influence of current. It has been Polarity Straight (electrode negative and workpiece
observed that with increase in current values, MRR positive)
increases for the three fluids. It is attributed to many rea- Electrode material Electrolytic grade copper (99.7%)
sons. With increase in current values, more number of Workpiece material M238 HH grade (P20 þ ) cold-worked die steel
electrons strike the work surface and raise the surface (plastic mold steel)
temperature. Therefore, more volume of work material Flushing type Submerged single-jet flushing
Dielectric fluid Biodielectrics BD1, BD2, and kerosene
Machining time for 10 minutes
each sample
TABLE 4.—Experimental control parameters and its levels.
Electrode shape and Circular rod with /20 mm
Current (A) 3,6,9,12,15,18 size
Pulse ON time (m sec) 21,50,100,200,400,600 Work material size and Rectangular plate with dimensions of
Pulse OFF=interval time ( msec) 6,11,20,30,40,75 shape 110  75  15 mm
Gap voltage (KV) 30,40,50,60,70,80 Duty factor (%) 60%–70%
544 J. B. VALAKI AND P. P. RATHOD
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FIGURE 2.—Electric discharge machined workpiece Samples using (a) BD1, (b) BD2, (c) kerosene, and (d) electrode sample.

Figure 3(b) represents the comparative performance behaviour is attributed to striking of more number of
of EWR under the influence of current. Results indi- positive ions on the electrode surface, resulting in a
cated that EWR increases with increase in current. This higher thermal state of electrodes which eventually

FIGURE 3.—Influence of current on (a) MRR, (b) EWR, and (c) RWR.
GREEN DIELECTRICS FOR SUSTAINABLE ELECTRIC DISCHARGE MACHINING 545

contributed to erosion of low melting point electrode conductivity, viscosity, and oxygen content, which could
material [31]. BD1 and BD2 resulted in approximately have maintained higher energy levels of the electrode
100% and 275% higher EWR, respectively, compared which intensify the oxidation and subsequent melting
to kerosene for the same set of parameters. The resulted and evaporation of the electrode material [28, 30].
higher EWR may be due to higher oxygen content in Figure 4(a) indicates the influence of gap voltage on
BD1 and BD2 [29] that could have produced intense MRR. It can be noticed that MRR decreases with
oxidation and highly conductive discharge channel, increase in gap voltage for the three dielectrics. Gap
allowing more number of ions to strike on the electrode voltage relates to the width of sparking gap. Higher
surface. gap voltage widens the sparking gap [32] and hence
Figure 3(c) shows the relative performance for RWR decreases the spark energy density, which eventually
at various current values. It can be seen that higher decreased MRR. Average MRR for BD1 is 15% higher
RWR was obtained at low current values, and it and BD2 is 145% higher than kerosene. Higher MRR
decreased up to 9A current and then it increased. It is values for BD1 and BD2 are attributed to higher BD
attributed to the fact that at lower current, lower electri- voltage, which allowed higher spark energy density due
cal conductivity of the partially ionized state of the to delayed dielectric breakdown [28].
plasma channel hinders the electron movement toward Comparative performance of EWR under the influ-
the electrode surface which in turn decreases the RWR ence of gap voltage for the three dielectrics is shown in
[19]. Increase in the current results in higher erosion of Fig. 4(b). It has been observed that EWR decreases with
workpiece due to higher thermal energy. Further increase in gap voltage. It is due to enlargement of
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increase in the current value beyond 9A, due to the sparking gap when the gap voltage increases [32]. It
highly conductive nature of the plasma channel, causes minimizes the intensity of striking of positive ions on
more number of positive ions to strike with the electrode the electrode surface and reduces the electrode wear.
surface to increase EWR, which in turn results in Moreover, wider sparking gap reduces energy density
increased RWR. Average RWR for BD1 is 60% higher in the machining gap, hence resulting in a decreasing
and BD2 is 45% higher than kerosene. Higher RWR EWR pattern. Compared to kerosene, BD1 produced
for BD1 and BD2 may be due to higher thermal 25% higher EWR and BD2 produced 150% higher

FIGURE 4.—Influence of gap voltage on (a) MRR (b) EWR, and (c) RWR.
546 J. B. VALAKI AND P. P. RATHOD

EWR. The resulted higher EWR for BD1 and BD2 may evaporation phenomenon and hence resulted in higher
be due to delayed dielectric breakdown because of MRR for the selected fluids [25, 26, 28]. However, the
higher BD voltage and concentrated spark energy energy density of electrical discharge reduces for higher
because of higher viscosity in the case of BD1 and Ton beyond a threshold value, i.e., 100 msec. It has been
BD2 [33]. noticed that average MRR is 26% higher for BD1 and
Figure 4(c) indicates the results of RWR under the 225% higher for BD2 compared to kerosene. The
influence of gap voltage. It can be seen that gap voltage resulted higher MRR may be due to higher thermal con-
has limited influence on RWR. At higher voltage, attack ductivities of BD1 and BD2 which could have ensured
of positive ions on the electrode surface is more severe better transfer of thermal energy toward the sparking
than attack of electrons on work surface due to wider area. Moreover, lower specific heat of BD1 and BD2
gap distance. Hence, RWR increases at higher voltage improves heat utilization ratio and higher viscosity
values. Average RWR obtained using BD1 is 35% higher enhanced debris evacuation tendency to increase MRR
and 23% lower for BD2 compared to kerosene. Higher [30].
RWR for BD1 may be due to higher viscosity and BD Figure 5(b) indicates the influence of Ton on EWR. It
voltage of BD1 which could have accumulated high can be seen that with increase in Ton values, EWR
energy in electrode resulting in more erosion of the increased initially, reached maximum, and decreased
electrode compared to the workpiece. Moreover, lower thereon. This behavior is similar to the work of some
RWR of BD2 may be due to higher viscosity and researchers [26–28, 30]. It can be attributed to the avail-
thermal conductivity of BD2 which could have trans- ability of more time for positive ions to strike the elec-
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ferred more energy toward work material to erode more trode surface because of increase in Ton which
workpiece material than electrode material. eventually increased EWR. However, with further
Figure 5(a) shows the performance of MRR at various increase in Ton, wider discharge channel weakens the dis-
levels of Ton. The results obtained portray that MRR charge energy density and plasma flushing efficiency to
increases with increase in Ton up to 100 msec and with reduce EWR [26]. It is noted that compared to kerosene,
further increase in Ton, it shows a declining pattern. BD1 and BD2 resulted in 66% and 121% higher EWR,
With increase in Ton, discharge channel becomes wider respectively. It is due to the reason that BD1 and BD2
and spark discharge energy was available for longer have less number of carbon atoms than kerosene [29]
duration, which eventually prolonged melting and and at higher Ton, more carbon atoms decompose and

FIGURE 5.—Influence of Ton on (a) MRR, (b) EWR, and (c) RWR.
GREEN DIELECTRICS FOR SUSTAINABLE ELECTRIC DISCHARGE MACHINING 547

deposit on the electrode surface in the case of kerosene discharge channel and hence reduces the area for striking
than for BD1 and BD2 [9, 34]. The resulted lower positive ions on the work surface [35]. Moreover, higher
EWR in the case of kerosene may be due to the Toff allows proper deionization; thus higher energy is
deposited carbon layer on the electrode surface that expensed for reionization of the dielectrics [32]. Lower
could have eroded lesser electrode material. Moreover, pulse frequency and consequently availability of lesser
resulted higher EWR in BD1 and BD2 may be due to discharge energy for melting and vaporizing resulted in
higher viscosities, which could have hindered heat trans- a lower MRR [31, 36]. BD1 resulted in 28% higher
fer toward the workpiece to accumulate more heat into MRR and BD2 resulted in 146% higher MRR compared
electrode surface causing increased erosion of electrode to kerosene. Higher MRR obtained may be due to higher
volume [30]. thermal conductivities and lower specific heats of BD1
Effect of Ton on the relative performance for RWR is and BD2, which could have helped to sustain the ionized
shown in Fig. 5(c). It can be seen that increase in Ton state for longer duration and longer erosion cycles[ ].
decreases the RWR. Higher pulse duration allows more Figure 6(b) indicates the influence of Toff on EWR. It
time for energy dissipation in the sparking gap. More- can be seen that Toff affects EWR to a small extent only.
over, higher thermal conductivity of copper electrode Higher pulse interval time minimizes the chances of
minimizes the energy concentration and results in lesser unwanted arcing and also makes discharge channel
electrode material erosion compared to the work smaller [37]. Results indicated that BD1 and BD2
material, which in turn reduces RWR [26]. Comparative produce 70% and 130% higher EWR, respectively,
results indicated that BD1 generates 30% higher EWR compared to kerosene. The resulted higher EWR in
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and BD2 resulted in 7% lower RWR compared to kero- the case of BD1 and BD2 may be attributed to higher
sene. Resulted lower RWR in the case of BD2 is due to spark energy density because of higher BD voltage and
higher viscosity of BD2 which could have increased the viscosity than kerosene [30, 33].
energy density [30] and higher thermal conductivity Figure 6(c) indicates the relative performance of RWR
allowed more heat transfer toward the work material. under the effect of Toff. It can be seen that the effect of Toff
Figure 6(a) indicates the comparative performance of on RWR is less significant. It is due to the fact that Toff
MRR under the influence of Toff. The results obtained affects MRR and EWR equally, and hence RWR is not
show that MRR decreases with increase in Toff values. affected significantly [32]. Longer Toff time allows proper
Increase in Toff indicates lower energy transfer per unit deionization of the dielectric and mitigates unfavorable
time. Higher Toff value results in smaller plasma arcing, and improved stability of sparking cycles

FIGURE 6.—Influence of Toff on (a) MRR, (b) EWR, and (c) RWR.
548 J. B. VALAKI AND P. P. RATHOD

TABLE 6.—Summary of relative performance comparison of BD1 and BD2 volume alters dimensional and geometrical accura-
w.r.t. kerosene. cies of the electrode at a faster rate. It gives less unit
S. No. Dielectric fluid Parameters MRR EWR RWR
production per electrode. Hence, tooling cost can be
higher in the case of biodielectrics.
1 BD1 Current 138 200 160 (c) BD1 and BD2 exhibited response patterns similar to
Gap voltage 126 166 135 kerosene for MRR, EWR, and RWR. It is an indi-
Ton 128 169 130 cation that material process mechanics and erosion
Toff 115 125 107 phenomenon for biodielectrics are similar to kero-
2 BD2 Current 265 375 145
sene. This proves the feasibility of biodielectrics for
Gap voltage 325 221 77
Ton 246 230 93
EDM. BD2 is found to be the best fluid for MRR
Toff 245 250 103 and RWR followed by BD1 and kerosene.
(d) Results of ANOVA indicates that current is the most
significant parameter for MRR and EWR. BD1 and
BD2 resulted in 38% and 165% higher MRR,
TABLE 7.—Summary of the results of ANOVA analysis. respectively, than kerosene. In addition, BD1 and
BD2 resulted in 100% and 275% higher EWR than
Response kerosene.
parameter Kerosene BD1 BD2
(e) As per the ANOVA results, pulse on time is the most
MRR Current—71% Current—82% Current—77% significant parameter for RWR. Under the influence
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EWR Current—56% Pulse on Current—84% Current—95% of Ton, BD1 produced 30% higher RWR, while
time—41% BD2 produced 7% lower RWR than kerosene.
TWR Pulse on time—96% Pulse on Pulse on
time—99% time—82%

ACKNOWLEDGMENTS
minimizes the variation in erosion rates [37]. Results The authors wish to express their gratitude to Prof.
obtained for RWR is 7% higher for BD1 while BD2 Bharat C Khatri, L.D. College of Engineering, Ahmeda-
shows 3% higher RWR compared to kerosene. The results bad, for extending his full remarks in improving the
obtained indicate that the relative performance of BD1 quality of the manuscript. The authors also thank Dr
and BD2 are similar to that of kerosene in terms of RWR. Pratyush Maiti, Senior Principal Scientist, Biodiesel
A summary of the relative performance of BD1 and Research Laboratory, CSMCRI, Bhavnagar (A CSIR,
BD2 in percentage with respect to kerosene under the New Delhi Research laboratory), and Ms. Hetal
influence of the four input parameters is presented in Bosamiya, project coordinator, for extending their
Table 6. valuable help in the preparation and testing of biofluids
ANOVA has been performed to analyze the contri- for this research. Special thanks go to Commissionerate
bution of input parameters on the response parameters, of Technical Education, Gujarat state, India, for
i.e., MRR, EWR, and RWR. MINITAB 16 statistical providing infrastructural and moral support to carry
analysis software was used to perform ANOVA. out this research work.
ANOVA results are obtained using general linear model
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