Microelectrical Discharge Machining: A Suitable Process for Machining Ceramics

Schubert, Andreas; Zeidler, Henning; Kühn, Ralf; Hackert-Oschätzchen, Matthias

doi:10.1155/2015/470801

Cited by 23 publications

(10 citation statements)

References 24 publications

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“…The amount of material removed is very small, and is flushed away with the continuously flowing fluid. The downward movement of the tool will produce the desired shape on the workpiece [7] [13]. Many attempts have been made by the researches to find the suitable method of machining.…”

Section: Principle Of Edmmentioning

confidence: 99%

Electrical Discharge Machining of Al2O3 and Si3N4 Ceramics; A Research

2019

IJRTE

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Ceramic materials which have high hardness and brittleness cannot be machined by traditional machining process because of their low efficiency and feasibility. But in non-traditional machining process, it overcomes these limitations proving it to be very useful in manufacturing process. In this review paper we are discussing about electrical discharge machining (EDM) process on Al2O3 and Si3N4 ceramic materials which are machine able. EDM parameters like material removal rate (MRR), tool wear rate (TWR), surface finish are discussed. EDM is very much suitable for ceramic materials because of its high surface finish, accuracy and efficiency.

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Section: Principle Of Edmmentioning

confidence: 99%

Electrical Discharge Machining of Al2O3 and Si3N4 Ceramics; A Research

2019

IJRTE

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“…Figure 5 shows the classification of ceramics based on their conductivity values. The minimum electrical conductivity required for electrical discharge machining is about 10 −2 /Ωcm [55]. All metallic materials fulfil this demand.…”

Section: Ceramic Materialsmentioning

confidence: 99%

“…This allows the machining of geometrical features with diameter of less than 5 µm and a depth of less than 1 µm. In such conditions, the achievable surface roughness is lower than 1 µm [55]. The precision and accuracy of the final products are much higher in micro-EDM [76].…”

Section: Principle Of Edmmentioning

confidence: 99%

Electro-Discharge Machining of Ceramics: A Review

et al. 2018

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Conventional machining techniques of ceramics such as milling, drilling, and turning experience high cutting forces as well as extensive tool wear. Nevertheless, non-contact processes such as laser machining and electro-discharge machining (EDM) remain suitable options for machining ceramics materials, which are considered as extremely brittle and hard-to-machine. Considering the importance of ceramic machining, this paper attempts to provide an insight into the state of the art of the EDM process, types of ceramics materials and their applications, as well as the machining techniques involved. This study also presents a concise literature review of experimental and theoretical research studies conducted on the EDM of ceramics. Finally, a section summarizing the major challenges, proposed solutions, and suggestions for future research directions has been included at the end of the paper.

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“…After finishing the AE, a layer of pyrolytic carbon (PyC) is deposited on the workpiece surface disassociating the carbonic dielectric in absence of oxygen and at a temperature of 1000-20000C. In experimental investigations it is observed that during the R-C pulse micro-EDM of nonconductive ceramics, pulse-off time is longer than that in conductive materials and effect of alternating thermal stress resulting spalling in addition to melting and evaporation [Chen et al, 2010;Sabur et al, 2013;Schubert et al, 2011;Schubert et al, 2015]. Sometimes, spalling becomes dominant over other removal mechanisms.…”

Section: Introductionmentioning

confidence: 99%

Micro Electro Discharge Machining of Nonconductive Ceramic: The Issue of Spalling

Ali¹,

Sabur²,

Maleque³

2018

IJET

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Nonconductive ceramic materials are used in many engineering applications such as car brake, turbine blade, and hip-bone replacement because of its high dimensional accuracy, corrosion and wear resistant, and biocompatibility. These materials are usually processed with diamond grinding and limited laser applications such as cutting, drilling and scribing. Specific shapes and profiles are still difficult and costly to machine using these processes. Electrical discharge machining (EDM), extensively used for various shapes and profiles on conductive materials having minimum electrical conductivity of 0.10 S.cm-1. It is not directly applicable on nonconductive ceramic materials due to its very low electrical conductivity (<10-10 S.cm-1). However, recently EDM is used on nonconductive materials with the aid of assisting electrode to initiate the spark between conductive tool electrode and nonconductive workpiece. The available material removal models of EDM are based on single spark erosion with uniform melting and vaporization of workpiece materials. However, in EDM of nonconductive ceramics, material removal is not uniform because of random spalling due to alternating thermal stress. In addition, it is difficult to create single spark erosion on a nonconductive ceramic workpiece as initial sparks are occurred between tool electrode and assisting electrode attached to workpiece. This paper presents the empirical factor for the estimation of spalling along with melting and vaporization through experimental study. Model of material removal rate as a function of capacitance and voltage are developed in micromachining of nonconductive zirconium oxide (ZrO 2 ) using (R-C) pulse type micro-EDM. The single spark erosion volume is derived from the fundamental principle of melting and vaporization. An empirical correction factor is introduced to compensate random spalling and multi-spark erosion effect.

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Microelectrical Discharge Machining: A Suitable Process for Machining Ceramics

Cited by 23 publications

References 24 publications

Electrical Discharge Machining of Al2O3 and Si3N4 Ceramics; A Research

Electrical Discharge Machining of Al2O3 and Si3N4 Ceramics; A Research

Electro-Discharge Machining of Ceramics: A Review

Micro Electro Discharge Machining of Nonconductive Ceramic: The Issue of Spalling

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