Experimental investigation on micro ED milling of inconel alloy with SiC nano powder mixed Pongamia BD at different parametric condition

μED-milling is an excellent micro machining process for machining of complex micro structures on conducting materials. In this paper, the feasibility of SiC nano powder mixed Pongamia BD as a dielectric medium while μED-milling of Inconel 718 alloy at different parametric settings namely capacitance (10 nf, 100 nf, 400 nf), powder concentration (0 g l⁻¹, 0.1 g l⁻¹, 0.3 g l⁻¹) and voltage (120 v, 130 v, 140 v) is analysed. Further, the craters dimensions are correlated with the 3D roughness parameters (Spk, Sk and Svk) in this investigation. Lower settings of capacitance (10 nF) offered a maximum MRR (601767.1 μm³ s⁻¹) compared to intermediate (398080.62 μm³ s⁻¹) and higher (273498.29 μm³ s⁻¹) settings of capacitance. MRR is increased around 1.3 times with Pongamia BD compared to SiC nano powder mixed Pongamia BD at considered parametric settings. Crater diameter is decreased by 24.1% with SiC nano powder mixed Pongamia BD due to lesser amount heat transfer to workpiece. Droplet angle of machined surface with SiC nano powder mixed Pongamia BD is 20% higher than Pongamia BD at considered parametric settings. Capacitance and voltage have the significant influence on crater diameter and roughness. Maximum MRR (1034239.41 μm³ s⁻¹) is achieved with machining condition (10 nF, 120 V, 0 g l⁻¹) for considered biodiesels. RLT appears to be higher around 27% with the processed surface of SiC nano powder mixed Pongamia BD as compared to Pongamia BD due to reaction of powder particles with work material. 3D roughness parameters (Spk, Sk and Svk) were greatly reduced due to inclusion of powder in biodiesels. Sk (core zone) are decreased (42.8%) with 0.3 g/l SiC nano powder mixed Pongamia BD compared to Pongamia BD.