Understanding novel assisted electrode from a theoretical and experimental perspectives for EDM of aluminum nitride ceramics

Rashid, Asif; Perveen, Asma; Jahan, Muhammad P.

doi:10.1007/s00170-021-07660-9

Cited by 6 publications

(5 citation statements)

References 26 publications

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“…Micro EDM differs from traditional EDM as micro EDM has a comparatively lower discharge energy level, smaller electrodes, and lower axis resolution. Micro EDM is now capable of machining complex 3D micro-features in a wide range of materials, from non-conductive [ 96 ] to semi-conductive materials [ 97 ], with high aspect ratios, such as micro-holes, micro-electrodes or shafts, micro-molds, etc., irrespective of the hardness of the workpiece. In recent years, the EDM process has also found application at nano scale for various applications such as nano-pores for DNA detection devices and nano-holes for next generation fuel injection nozzles [ 98 ].…”

Section: Non-conventional Machining Of Bmgmentioning

confidence: 99%

“…Figure 19 shows the machined surface morphologies of BMG obtained at different settings of voltages [ 100 ]. The XRD patterns of the machined surface, as shown in Figure 20 , show the presence of ZrC on the machined surface [ 96 ]. As there was no or minimum presence of ZrO 2 on the machined surface, there was minimum crystallization on the machined surface.…”

Section: Non-conventional Machining Of Bmgmentioning

confidence: 99%

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Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Jahan,

Niraula,

Nafi

et al. 2024

Micromachines

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Bulk metallic glasses (BMGs) are growing in popularity prominently due to their potential in micro-electromechanical systems (MEMSs) and aerospace applications. BMGs have unique mechanical properties, i.e., high strength, hardness, modulus of elasticity, and wear resistance, due to their disordered atomic structure. Due to their unique mechanical properties and amorphous structures, machining of BMGs remains a challenge. This paper aims to carry out a detailed literature review on various aspects of the machining of bulk metallic glasses using both conventional and non-conventional processes, including experimental approaches, modeling, statistical findings, challenges, and guidelines for machining this difficult-to-machine material. Conventional machining processes were found to be challenging for machining bulk metallic glasses due to their high hardness, brittleness, and tendency to convert their amorphous structure into a crystalline structure, especially at the machined surface and sub-surface. Although their high electrical conductivity makes them suitable for machining by non-conventional processes, they impose new challenges such as heat-affected zones and crystallization. Therefore, the successful machining of BMGs requires more in-depth analysis of cutting forces, tool wear, burr formation, surface finish, recast layers or heat-affected zones, crystallization, and mechanical property changes among different varieties of BMGs. This review paper provides guidelines emerging from in-depth analysis of previous studies, as well as offering directions for future research in the machining of BMGs.

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Section: Non-conventional Machining Of Bmgmentioning

confidence: 99%

Section: Non-conventional Machining Of Bmgmentioning

confidence: 99%

Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Jahan,

Niraula,

Nafi

et al. 2024

Micromachines

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“…Nitride-based UHTCMCs have been verified to be capable of machining with EDM [137,138]. Using the Taguchi L25 orthogonal test, Selvarajan et al [139] investigated the EDM characteristics of Si 3 N 4 -TiN intermetallic compounds and ceramic composites.…”

Section: Electrical Discharge Machining Of Nitride-based Uhtcmcsmentioning

confidence: 99%

Review of Research Progress in Nontraditional Machining of Ultrahigh-Temperature Ceramic Matrix Composites

et al. 2023

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Ultrahigh-temperature ceramic matrix composites are currently among the most promising high-temperature-resistant materials, owing to their high-temperature strength, high-toughness and excellent corrosion resistance; they are widely used in national defense and aerospace fields. However, it is a difficult material to machine, and high precision is difficult to achieve using traditional machining methods. Nontraditional machining methods are not constrained by material physical and mechanical properties, and good surface quality is easily obtained, which is an important direction in the field of ultrahigh-temperature ceramic matrix composites. This paper summarizes the recent nontraditional machining methods utilized in the fabrication of ultrahigh-temperature ceramic matrix composites. Firstly, various nontraditional machining methods for ultrahigh-temperature ceramic matrix composites based on borides, carbides and nitrides are reviewed, and the machining performances under different machining conditions are compared. Subsequently, the problems and challenges of ultrahigh-temperature ceramic matrix composite nontraditional machining are summarized and discussed. Lastly, the future development path of nontraditional machining methods for ultrahigh-temperature ceramic matrix composites is summarized and predicted.

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“…Rashid et al [ 137 ] investigated the machining of an electrically non-conductive aluminum nitride (AlN) ceramic surface by using micro-EDM. It was found that the material was removed due to the combination of melting, evaporation, and thermal spalling.…”

Section: Edm-based Novel Techniques Of Surface Modification and Appli...mentioning

confidence: 99%

“… SEM images showing micro-holes produced in AlN by the micro-EDM process [ 137 ]. (With kind permission from Springer).…”

Section: Figurementioning

confidence: 99%

Functional Surface Generation by EDM—A Review

Nafi

Jahan

2022

Micromachines

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Electro-discharge machining (EDM) removes electrically conductive materials by high frequency spark discharges between the tool electrode and the workpiece in the presence of a dielectric liquid. Being an electrothermal process and with melting and evaporation being the mechanisms of material removal, EDM suffers from migration of materials between the tool and the workpiece. Although unwanted surface modification was considered a challenge in the past for many applications, this inherent nature of the EDM process has recently become of interest to the scientific community. As a result, researchers have been focusing on using the EDM process for surface modification and coating by targeted surface engineering. In order to engineer a surface or generate functional coatings using the electro-discharge process, proper knowledge of the EDM process and science of electro-discharge surface modification must be understood. This paper aims to provide an overview of the electro-discharge surface modification and coating processes, thus assisting the readers on exploring potential applications of EDM-based techniques of surface engineering and coating generation. This review starts with a brief introduction to the EDM process, the physics behind the EDM process, and the science of the surface modification process in EDM. The paper then discusses the reasons and purposes of surface modification and coating practices. The common EDM-based techniques reported in the literature for producing coatings on the surface are discussed with their process mechanisms, important parameters, and design considerations. The characterization techniques used for the analysis of modified surfaces and coating layers, as well as the tribological and surface properties of modified surfaces or coatings are discussed. Some of the important applications of EDM-based surface modification and coating processes are generating surfaces for protective coating, for aesthetic purposes, for enhancing the biocompatibility of implants, for improving corrosion resistance, for improving wear resistance, and for improving tribological performance. The current state of the research in these application areas is discussed with examples. Finally, suggestions are provided on future research directions and innovative potential new applications of the electro-discharge-based surface engineering and coating processes.

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Understanding novel assisted electrode from a theoretical and experimental perspectives for EDM of aluminum nitride ceramics

Cited by 6 publications

References 26 publications

Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Multi-Scale Traditional and Non-Traditional Machining of Bulk Metallic Glasses (BMGs)—Review of Challenges, Recent Advances, and Future Directions

Review of Research Progress in Nontraditional Machining of Ultrahigh-Temperature Ceramic Matrix Composites

Functional Surface Generation by EDM—A Review

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