Development of Trends and Methodologies for Shaping Ceramics by Electrical Discharge Machining: A Review

2019 ◽  
Author(s):  
Asif Rashid ◽  
Muhammad P. Jahan ◽  
Asma Perveen ◽  
Jianfeng Ma
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Hardness ◽  
High Strength ◽  
Ceramic Materials ◽  
Machining Process ◽  
Future Research ◽  
Great Resistance ◽  
Hard And Brittle Materials ◽  
Superior Corrosion Resistance

Abstract Ceramic materials possess excellent properties like high hardness, superior corrosion resistance and great resistance to wear. These materials are low in density and demonstrate high strength to wear ratio. There is an increasing need to machine these hard and brittle materials as they have various engineering applications. The distinguishing properties of ceramics do not allow them to be machined by conventional processes. Electrical discharge machining (EDM) is a non-conventional process and a viable option to machine and generate complex shapes in hard materials. EDM can be used on materials irrespective of its hardness and wear resistance as it is a non-contact machining process and no active force is applied between the workpiece and electrode during machining. As EDM requires the workpiece to be electrically conductive, machining ceramics by this process is a challenge. Alterations need to be carried out in order for insulating ceramics to be machined by this process. This paper discusses the basics of EDM process and its control parameters. A classification of ceramic materials based on their electrical conductivity is established and their relevance to the respective material removal mechanisms have been identified. Different approaches to successfully machine ceramics by EDM have been reviewed. The challenges and modifications of each method have been discussed. An outline and expectations for machining a particular ceramic material and its composites have been generated. Finally, the prospects of future research in this area have been identified.

scholarly journals Electrical Discharge Machining of Al2O3 and Si3N4 Ceramics; A Research

2019 ◽  
Vol 8 (2S8) ◽  
pp. 1806-1808
Keyword(s):  
Surface Finish ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Surface ◽  
High Hardness ◽  
Ceramic Materials ◽  
Machining Process ◽  
Low Efficiency ◽  
Edm Process

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.

The surface integrity of ultra-fine grain steel, Electrical discharge machined using Iso-pulse and resistance–capacitance-type generator

2020 ◽  
Vol 234 (4) ◽  
pp. 564-573
Author(s):  
Mohammad S Mahdieh
Keyword(s):  
Surface Integrity ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Strength ◽  
Functional Method ◽  
Machining Process ◽  
Machining Parameters ◽  
Fine Grained ◽  
Hardness Tester ◽  
Angular Pressing

Ultra-fine grained materials with high strength and low weight are eventually considered to be used in industries. To produce ultra-fine grained materials, equal channel angular pressing is a functional method, imposing severe plastic deformation on the workpiece. Electrical discharge machining is an indispensable process in manufacturing industrial parts with high accuracy and precision. However, electrical discharge machining has thermo-physical consequences, damaging the surface layers of the workpiece. On the other hand, the ultra-fine grained materials are thermodynamically unstable and tend to microstructural evolution. Thus, electrical discharge machining process affects the ultra-fine grained materials more than coarse grain materials. In this study, the effects of electrical discharge machining on the ultra-fine grained steel were investigated and the undesirable influences of the electrical discharge machining were diminished by adjusting the electrical discharge machining parameters. The ultra-fine grained steel samples were electrical discharge machined in two methods including Iso-pulse (roughing mode and finishing mode) and with resistance–capacitance-type generator. The surface integrity parameters, including thickness and microstructure of the recast layer and heat-affected zone, the cracks density and hardness, which for all three types of samples, were investigated by scanning electron microscopy, optical microscopy, X-ray diffraction technique, and micro-hardness tester. The results show that electrical discharge machining with resistance–capacitance-type generator has the minimum effects on the surface integrity of the ultra-fine grained samples because of the different material removal mechanism of resistance–capacitance-type electrical discharge machining.

Machining of Through Holes in Non-Conductive Aluminum Nitride Ceramic Using Electrical Discharge Machining Process

2020 ◽  
Author(s):  
Asif Rashid ◽  
Muhammad P. Jahan ◽  
Asma Perveen ◽  
Jianfeng Ma
Keyword(s):  
Aluminum Nitride ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Weight Ratio ◽  
Ceramic Materials ◽  
Machining Process ◽  
Machining Parameters ◽  
Eds Analysis ◽  
Electrode Method

Abstract Ceramic materials are known for their high hardness and strength-to-weight ratio, resistance to wear, and chemical inertness. These materials can be deployed at elevated temperature even to the limit where super alloys cannot be used. The distinctive properties of ceramics make them difficult to machine by conventional processes because of their brittleness. Electrical discharge machining (EDM) is a non-contact machining process that can machine any workpiece irrespective of its hardness, as long as the material is electrically conductive. Therefore, the challenge that comes with the EDM of ceramics is the electrical non-conductivity. In this study, an innovative method (modified assisted-electrode method) has been proposed, which can be used to successfully machine through holes in pure and non-conductive ceramic materials using the EDM process. The effect of machining parameters and conductive coating has been studied. In addition, the possible material removal method has been investigated using the scanning electron microscope (SEM) and energy dispersive X-ray spectroscopy (EDS) analysis. It is found that multi-layer coating with conductive copper tape sandwiched with graphene and carbon nanotubes in between the tape worked as a successful assistive electrode method. The SEM and EDS analysis indicates melting and thermal spalling as possible material removal mechanisms during EDM of electrically non-conductive Aluminum nitride (AlN) ceramics. The deposition of carbon at the edge of the holes indicate generation of conductive carbon layer favoring continuous sparking during the machining process, and this makes the EDM of non-conductive AlN possible. The walls of the drilled holes become conductive and allow the machining to go through even beyond the conductive layer range. The performance characteristics depends on both the electrical parameters and assistive electrode method.

Optimization of Micropencil Grinding Tools Via Electrical Discharge Machining

2019 ◽  
Vol 141 (3) ◽  
Author(s):  
Peter A. Arrabiyeh ◽  
Maximilian Dethloff ◽  
Christopher Müller ◽  
Benjamin Kirsch ◽  
Jan C. Aurich
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cubic Boron Nitride ◽  
Machining Process ◽  
Depth Of Cut ◽  
Parameter Study ◽  
Micro Electrical Discharge Machining ◽  
Hard And Brittle Materials ◽  
Novel Method ◽  
Abrasive Layer

Micropencil grinding tools (MPGTs) are micromachining tools that use superabrasives like diamond and cubic boron nitride (cBN) grits to manufacture complex microstructures in a broad range of hard and brittle materials. MPGTs suffer from a rather low tool life, when compared to other more established microprocessing methods. It was documented that when used on hardened steel workpieces, MPGTs suffer from a large amount of adhesions, mostly located at the pivot point of the tool. These adhesions lead to the clogging of the abrasive layer and ultimately in tool failure. Another problem this machining process suffers from is the formation of substructures (smaller channels inside the microchannels). The pivot is usually less prone to abrasive wear, has higher protrusion, and is therefore responsible for the deepest substructures. These substructures can easily take up half the depth of cut, obstructing the function of machined microchannels—it is one of the major flaws of this micromachining process. A micro-electrical discharge machining method (μEDM) can solve these issues by manufacturing a cavity at the pivot of these tools. A novel method that uses measurement probes to position the substrate above the μEDM electrode is implemented and a parameter study to determine the cavity manufacturing parameters is conducted for substrates with diameters < 40 μm. The goal is to demonstrate the first ever complete and reliable manufacturing process for MPGTs with a cavity and to demonstrate the advantages they provide in a machining process when compared to regular MPGTs.

Recent Developments in Wire Electrical Discharge Machining

2019 ◽  
pp. 125-152
Author(s):  
Nadeem Faisal ◽  
Sumit Bhowmik ◽  
Kaushik Kumar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrical Discharge Machine ◽  
High Strength ◽  
Optimization Methods ◽  
Machining Process ◽  
Machining Processes ◽  
Accuracy And Precision ◽  
Recent Developments ◽  
Conventional Machining

The tremendous growth of manufacturing industries and desired need of accuracy and precision has put a great importance on non-traditional machining processes. Metal and non-metals having properties like high strength, toughness, and hardness is generally machined by non-conventional machining methods. One of earliest non-traditional machining that is still in use and being effectively utilized in industries is wire electrical discharge machine. This machining technique gives a tough line of competition to conventional machining process like milling, grinding, broaching, etc. Cutting intricate and delicate shapes with accuracy and precision gives this machining technique an edge over other conventional machining and non-conventional machining processes. This chapter provides an insight to various research and prominent work done in field of WEDM by various scientists, researchers, and academicians. The chapter also emphasizes various advantages and disadvantages of different modelling and optimization methods used. The chapter concludes with some recommendations about trends for future WEDM researchers.

Residual Stress Analysis of Polycrystalline Diamond after Electrical Discharge Machining

2013 ◽  
Vol 820 ◽  
pp. 106-109 ◽  
Author(s):  
M. Zulafif Rahim ◽  
Arash Pourmoslemi ◽  
Song Lin Ding ◽  
John Mo
Keyword(s):  
Residual Stress ◽  
Electrical Discharge ◽  
Cutting Tool ◽  
Electrical Discharge Machining ◽  
Polycrystalline Diamond ◽  
High Hardness ◽  
Machining Process ◽  
Hard Materials ◽  
Advanced Machining ◽  
Pcd Tools

The extreme hardness of Polycrystalline Diamond (PCD) makes it an ideal choice for the machining of hard materials as a cutting tool. Due to the high hardness, fabrication of PCD tools relies on conventional abrasive grinding which suffers from low machining efficiency. Electrical discharge machining (EDM) is an advanced machining process and can be utilised to fabricate complicated PCD tools. High temperature of sintering and EDM processes creates residual stress inside PCD and can result in unmatured failure of PCD tools. This paper analyses the distribution of residual stress in PCD after electrical discharge machining process.

scholarly journals Optimization of Process Parameters of Electrical Discharge Machining Process for Performance Improvement

2019 ◽  
Vol 8 (11) ◽  
pp. 3830-3836 ◽  
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
High Strength ◽  
Machining Process ◽  
Machining Performance ◽  
Optimization Of Process Parameters ◽  
Unconventional Machining ◽  
Insight Into

Unconventional machining methods are used where conventional techniques are unachievable, inacceptable or cost ineffective. Number of unconventional techniques has been developed to achieve special machining conditions. When these methods are engaged properly, they provide several benefits over conventional methods. High strength alloys can be machined easily, complicated contours and difficult geometries with close tolerances and better surface topograph can be developed using unconventional processes. One of the most popular unconventional machining methods is electrical discharge machining. In this paper, the detailed investigation has carried out to give an insight into the progression of research in the domain of spark machining and optimizing important process variables of this type of machining. It has been found from the available literature that optimization of process parameters of electrical discharge machining can improve machining performance pertaining to material removal and surface finish. Identifying the research gaps and are presented under the heading analysis and discussion. Conclusions drawn from this work will be useful in carrying out research in the sphere of unconventional EDM.

scholarly journals Roughness analysis of composite based on aluminum alloys after electrical discharge machining process with use of different filtering methods

Mechanik ◽  
2017 ◽  
Vol 90 (4) ◽  
pp. 318-320
Author(s):  
Aneta Łętocha ◽  
Jolanta Cyboroń ◽  
Tatiana Miller
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cone Angle ◽  
Ceramic Materials ◽  
Machining Process ◽  
Gaussian Filter ◽  
Roughness Parameters ◽  
Alloy Base ◽  
Roughness Analysis ◽  
Process Measurements

Ceramic materials or metallic materials containing ceramic phases are very interesting cases in roughness measurement. They are characterised by more or less pored surface. This paper presents roughness analysis of composite material with aluminum alloy base (AlSi7Mg) with 10 vol. % of silicon carbide (SiC) and 10 vol. % of spherical graphite (Cg) additions. Surfaces of these samples were prepared using electrical discharge machining (EDM) process. Measurements were performed with use of contact TOPO 02 profilometer equipped with diamond stylus tip (2 μm radius and 60 degree cone angle). This machine is produced in The Institute of Advanced Manufacturing Technology. Measurements were analysed with use of three filtration methods: Gaussian filter, Robust Gaussian filter and Gaussian filter for surfaces having stratified functional properties. Height roughness parameters, roughness core parameters and volume parameters were calculated. Most proper filtering method, which gives credible results of roughness parameters, was chosen.

A study of stored energy in ultra-fined grained aluminum machined by electrical discharge machining

2016 ◽  
Vol 231 (23) ◽  
pp. 4470-4478 ◽  
Author(s):  
Mohammad S Mahdieh ◽  
Ramezan A Mahdavinejad
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Strength ◽  
Hardness Test ◽  
Industrial Applications ◽  
Recast Layer ◽  
Machining Process ◽  
Large Strains ◽  
Stored Energy ◽  
Scanning Calorimetry

Due to light weight and high strength, industrial applications of ultra-fined grain materials are becoming prevalent. Ultra-fined grain materials are produced by severe plastic deformation techniques such as equal channel angular pressing, which impose large strains on ultra-fined grain microstructure, resulting in accumulation of the lattice defects and dislocations and consequently increasing the stored energy. Due to high stored energy of ultra-fined grain materials, they are thermodynamically unstable and prone to microstructural evolutions. In order to manufacture industrials parts, applying machining methods such as electrical discharge machining is necessary. Electrical discharge machining is a thermo-electrical process that erodes the surface of the workpiece by high temperature sparks. The surface of the workpiece is melted and then suddenly quenched into dielectric, and eventually a very hard and brittle layer, known as recast layer, is formed. The recast layer and heat-affected zone are the source of microstructural changes that affect the special properties of the ultra-fined grain materials and their stored energy. In this study, the bulk and local stored energy of electrical discharge machined ultra-fined grain aluminum samples are measured via differential scanning calorimetry technique and micro-hardness test. In the following, the effects of the electrical discharge machining process on ultra-fined grain aluminum are investigated. The results show that electrical discharge machining process alters the stored energy of the ultra-fined grain materials.

Research on High-Speed Cutting of Cr12MoV Hardened Steel - A Review

2020 ◽  
Vol 15 ◽  
Author(s):  
Fei Sun ◽  
Guohe Li ◽  
Qi Zhang ◽  
Meng Liu
Keyword(s):  
High Speed ◽  
Cutting Temperature ◽  
High Hardness ◽  
High Strength ◽  
Hardened Steel ◽  
Parameters Optimization ◽  
Future Research ◽  
High Speed Machining ◽  
Machined Surface ◽  
Stamping Die

: Cr12MoV hardened steel is widely used in the manufacturing of stamping die because of its high strength, high hardness, and good wear resistance. As a kind of mainstream cutting technology, high-speed machining has been applied in the machining of Cr12MoV hardened steel. Based on the review of a large number of literature, the development of high-speed machining of Cr12MoV hardened steel was summarized, including the research status of the saw-tooth chip, cutting force, cutting temperature, tool wear, machined surface quality, and parameters optimization. The problems that exist in the current research were discussed and the directions of future research were pointed out. It can promote the development of high-speed machining of Cr12MoV hardened steel.

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