The Machining Characteristics of Insulating AlN Ceramics by EDM

2012 ◽  
Vol 523-524 ◽  
pp. 328-331
Author(s):  
Kensei Kaneko ◽  
Ken Yamashita ◽  
Yasushi Fukuzawa
Keyword(s):  
Thermal Conductivity ◽  
Removal Rate ◽  
Ceramic Materials ◽  
High Thermal Conductivity ◽  
Electrode Wear ◽  
Machining Time ◽  
Laser Method ◽  
Wear Ratio ◽  
Machining Properties ◽  
Machining Characteristics

AlN ceramic materials have high thermal conductivity and electrical insulation, prompting consideration of their use as a semiconducting material. Although AlN should be machined with a high accuracy of form and dimension to achieve products and components with requisite precision, mechanical and other machining methods such as the micro blasting technology or laser method cannot be used because of the brittleness and high thermal conductivity of AIN. Recently, we have succeeded in machining many insulating ceramics by EDM with the assisting electrode method. We have already machined many insulating ceramic materials such as Si3N4, ZrO2 and Al2O3. However, inferior machining characteristics were obtained with AlN than with other materials. In this study, the effects of several electrical discharge conditions were examined to obtain better machining properties, such as high material removal rate and a low electrode wear ratio. It was found that machining time decreased with an increase in capacitance, while the electrode wear ratio increased. In addition, the machining hole profiles were straight along the depth direction, and the shape of holes was non-tapered

Characteristics of Micro EDM for Insulating Aluminum Nitride Ceramics

2012 ◽  
Vol 579 ◽  
pp. 86-91 ◽  
Author(s):  
Kensei Kaneko ◽  
Yasushi Fukuzawa
Keyword(s):  
Thermal Conductivity ◽  
Electrical Discharge ◽  
Removal Rate ◽  
Ceramic Materials ◽  
Deionized Water ◽  
Electrode Wear ◽  
X Ray ◽  
Wear Ratio ◽  
Electrode Method ◽  
Assisting Electrode

Aluminum Nitride (AlN) ceramic materials have high thermal conductivity and electrical insulation, prompting consideration of their use as a semiconducting material. Although AlN should be machined with a high accuracy of form and dimension to achieve products and components with requisite precision, mechanical and other machining methods such as the laser method cannot be used because of the brittleness and high thermal conductivity of AIN. Recently, we have succeeded in machining many insulating ceramics by sinking (SEDM) and Wire-Electrical Discharge Machining (WEDM) with the assisting electrode method. We have already machined many insulating ceramic materials such as Si3N4, ZrO2 and Al2O3. However, inferior machining characteristics were obtained with AlN than with other materials. In this study, the effects of several electrical discharge conditions were examined to obtain better machining properties, such as high material removal rate and a low electrode wear ratio. It was found that machining time decreased with an increase in capacitance, while the electrode wear ratio increased. The electrode wear ratio of the W electrode was low, suggesting that it is suited for accurate machining of AlN. Additionally, the electrically conductive layer was analyzed using Energy Dispersive X-ray Spectrometry (EDS) and X-ray Diffraction (XRD). As a result, the architectural component of the EDMed AlN surface is considered mostly Al that is resolution of the workpiece. Therefore, in the EDM of AlN using the assisting electrode method, machinability using deionized water may be superior to dielectric oil. To investigate the effect of the dielectric working fluid, AlN was machined using deionized water and dielectric oil. In the case of machining with deionized water, the removal rate was faster and electrode wear ratio was lower, compared to dielectric oil.

Study of Electrode Wear Ratio of Piezoelectric Self-Adaptive Micro-EDM

2013 ◽  
Vol 589-590 ◽  
pp. 505-510
Author(s):  
De Zheng Kong ◽  
Qin He Zhang ◽  
Xiu Zhuo Fu ◽  
Ya Zhang
Keyword(s):  
Open Circuit Voltage ◽  
Removal Rate ◽  
Open Circuit ◽  
The Self ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Micro Edm ◽  
Traditional Concept ◽  
Wear Ratio ◽  
Self Adaptive

Micro Electrical discharge machining (Micro-EDM) is a non-traditional concept of machining. It is very suitable for machining micro parts of Micro-electromechanical Systems (MEMS). However, the application of micro-EDM is restricted for its own shortcomings such as poor material removal rate and high electrode wear ratio etc. In order to overcome this shortcoming, a new piezoelectric self-adaptive micro-EDM (PSMEDM) is developed based on inverse piezoelectric effect of piezoelectric ceramics and its working mechanism and characteristics have been analyzed in this paper. This machining method can realize the self-tuning regulation of discharge gap depending on the discharging conditions, facilitate removing the debris in the machining gap, reduce the occurrence of arcing and shorting and can realize the self-elimination of short circuits, thus the machining efficiency can be improved drastically. The tool electrode wear ratio (EWR) in machining is studied in this paper. Many experiments have been done and the effects of parameters on electrode wear ratio have been analyzed. Experimental results indicate that: 1) The EWR will rise with the increase of open-circuit voltage and main capacitance in circuit because the increase of open-circuit voltage and capacitance result in increase of single discharge energy. 2) The effect of resistance R1 on EWR is light. With the increase of resistance R1, the EWR will decrease slightly. 3) With the increase of resistance R2, the EWR will decrease firstly and then becomes to increase.

scholarly journals Influence of Different Tool Electrode Materials on Electrochemical Discharge Machining Performances

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1077
Author(s):  
Islam Md. Rashedul ◽  
Yan Zhang ◽  
Kebing Zhou ◽  
Guoqian Wang ◽  
Tianpeng Xi ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Electrical Conductivity ◽  
Electrode Materials ◽  
Removal Rate ◽  
Machining Accuracy ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Electrochemical Discharge Machining ◽  
Electrochemical Discharge ◽  
Micro Channels

Electrochemical discharge machining (ECDM) is an emerging method for developing micro-channels in conductive or non-conductive materials. In order to machine the materials, it uses a combination of chemical and thermal energy. The tool electrode’s arrangement is crucial for channeling these energies from the tool electrode to the work material. As a consequence, tool electrode optimization and analysis are crucial for efficiently utilizing energies during ECDM and ensuring machining accuracy. The main motive of this study is to experimentally investigate the influence of different electrode materials, namely titanium alloy (TC4), stainless steel (SS304), brass, and copper–tungsten (CuW) alloys (W70Cu30, W80Cu20, W90Cu10), on electrodes’ electrical properties, and to select an appropriate electrode in the ECDM process. The material removal rate (MRR), electrode wear ratio (EWR), overcut (OC), and surface defects are the measurements considered. The electrical conductivity and thermal conductivity of electrodes have been identified as analytical issues for optimal machining efficiency. Moreover, electrical conductivity has been shown to influence the MRR, whereas thermal conductivity has a greater impact on the EWR, as characterized by TC4, SS304, brass, and W80Cu20 electrodes. After that, comparison experiments with three CuW electrodes (W70Cu30, W80Cu20, and W90Cu10) are carried out, with the W70Cu30 electrode appearing to be the best in terms of the ECDM process. After reviewing the research outcomes, it was determined that the W70Cu30 electrode fits best in the ECDM process, with a 70 μg/s MRR, 8.1% EWR, and 0.05 mm OC. Therefore, the W70Cu30 electrode is discovered to have the best operational efficiency and productivity with performance measures in ECDM out of the six electrodes.

Study on the Effect of Tool Polarity and Tool Rotation during EDM of Non-Conductive Ceramics

2014 ◽  
Vol 941-944 ◽  
pp. 2127-2133 ◽  
Author(s):  
Nirdesh Ojha ◽  
Florian Zeller ◽  
Claas Mueller ◽  
Holger Reinecke
Keyword(s):  
Material Properties ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Ceramic Materials ◽  
Machining Process ◽  
Electrode Wear ◽  
Conductive Material ◽  
Tool Rotation ◽  
Edm Process

The ability to machine advanced ceramic materials such as ZrO2, SiC, and AlN is of high interest for various industries because of the extraordinary material properties that these ceramics possess. Once sintered, these ceramics are characterized with high mechanical strength, high thermal stability and high chemical inertness. Therefore it is extremely difficult to machine these ceramics with dimensions in few microns using traditional techniques. Electrical discharge machining (EDM) is an electro-thermal machining process used to structure conductive materials. By applying a conductive layer on top of the non-conductive material, the EDM process can also be used to machine the non-conductive material. This paper presents a study on the effect of tool polarity and tool rotation on the material removal rate and electrode wear ratio during the EDM process of non-conductive SiC, ZrO2 and AlN ceramics. The reasons for the variation in the material removal rates among the different ceramics are examined by comparing the material properties. Relatively lower value of flexural strength, fracture toughness and melting temperature is the reason for AlN ceramic to have the higher MRR than SiC and ZrO2 ceramics.

The Effect of EDM Die-Sinking Parameters on Machining Characteristics in Aluminum Alloy Machining

2015 ◽  
Vol 761 ◽  
pp. 303-307 ◽  
Author(s):  
Laily Suraya ◽  
M.A. Ali ◽  
N.I.S. Hussein ◽  
Mohd Razali Muhamad ◽  
Manshoor Bukhari ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Design Matrix ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Electrode Tool ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Machining Characteristics

The effect of machining parameters on machining characteristics for aluminium alloy LM6 (Al-Sil2) in Electrical Discharge Machining (EDM) die-sinking is studied. The objective of this project is to determine the relationship between the machining parameters including pulse-on time, pulse-off time, peak current and voltage with the machining characterictics such as Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (Ra). Copper materials having diameter 15mm was chosen as the electrode tool. Design of experimenent using Taguchi technique was employed to design experimental matrix that was used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that current and pulse off time significantly affect MRR, EWR and Ra while pulse on time and voltage are less significant in their effect on machining responses. Results show that using Taguchi as a design matrix, the best setting of optimum value for machining parameters to find the required machining responses can be obtained.

Influence of Workpiece Shape on MRR and EWR in EDM of Steel

2014 ◽  
Vol 903 ◽  
pp. 51-55 ◽  
Author(s):  
Alexis Mouangue Nanimina ◽  
Ahmad Majdi Abdul Rani ◽  
Mohd Amri Lajis ◽  
Turnad Lenggo Ginta ◽  
T.V.V.L.N. Rao
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Research Work ◽  
Electrode Wear ◽  
Wear Ratio ◽  
Flat Shape ◽  
Dielectric Flushing ◽  
Edm Process

Shape of workpiece, electrode orientation and flushing system play important role in electrical discharge machining (EDM) process. Low material removal rate and relatively high electrode wear ratio are some of the disadvantages of EDM process. This can be due to the flushing modes. Workpiece shape has a significant effect in effectiveness of dielectric flushing flow and orientation during EDM process. This research work is conducted to analyze the influence of various workpiece shapes. Square cavity, L shape, flat shape and U shape were machined with same cross-section electrode material. Test parameters are material removal rate (MRR) and electrode wear ratio (EWR). Experiment results show slight difference in MRR and EWR values for different shapes. U shape presents the highest MRR and the lowest EWR occurs in flat shape compared to cavity and L shapes. It can be concluded that flat and U shapes result in good EDM machining quality due to good dielectric flow and flushing conditions in the area of EDM machining.

scholarly journals Technical Model of Micro Electrical Discharge Machining (EDM) Milling Suitable for Bottom Grooved Micromixer Design Optimization

Micromachines ◽  
2020 ◽  
Vol 11 (6) ◽  
pp. 594 ◽  
Author(s):  
Izidor Sabotin ◽  
Gianluca Tristo ◽  
Joško Valentinčič
Keyword(s):  
Design Optimization ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Micro Edm ◽  
Efficient Design ◽  
Machining Time ◽  
Micro Electrical Discharge Machining ◽  
Technical Model

In this paper, development of a technical model of micro Electrical Discharge Machining in milling configuration (EDM milling) is presented. The input to the model is a parametrically presented feature geometry and the output is a feature machining time. To model key factors influencing feature machining time, an experimental campaign by machining various microgrooves into corrosive resistant steel was executed. The following parameters were investigated: electrode dressing time, material removal rate, electrode wear, electrode wear control time and machining strategy. The technology data and knowledge base were constructed using data obtained experimentally. The model is applicable for groove-like features, commonly applied in bottom grooved micromixers (BGMs), with widths from 40 to 120 µm and depths up to 100 µm. The optimization of a BGM geometry is presented as a case study of the model usage. The mixing performances of various micromixer designs, compliant with micro EDM milling technology, were evaluated using computational fluid dynamics modelling. The results show that slanted groove micromixer is a favourable design to be implemented when micro EDM milling technology is applied. The presented technical model provides an efficient design optimization tool and, thus, aims to be used by a microfluidic design engineer.

Effect of Surfactant on EDM of Low Conductivity Reaction-Bonded Silicon Carbide

2016 ◽  
Vol 701 ◽  
pp. 107-111
Author(s):  
Muhammad Raziman Abdul Razak ◽  
Pay Jun Liew ◽  
Nur Izan Syahriah Hussein ◽  
Qumrul Ahsan
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Weight Percentage ◽  
Wear Ratio ◽  
Optimum Weight ◽  
Span 80

This work was focused on improving machining performance of reaction-bonded silicon carbide (RB-SiC) ceramic material using an electrical discharge machine (EDM) with the aid of surfactant. The changes of material removal rate, electrode wear ratio and surface roughness were investigated under two different surfactants, namely Span 20 and Span 80. The surfactant was mixed with carbon nanofiber (CNF) and EDM oil prior to the experiment. Then, the mixture was homogenized in an ultrasonic homogenizer for 35 minutes. In order to investigate the effect of surfactant, different weight percentages which is 0.4wt%, 0.6wt% and 0.8wt% of surfactant were used. The experimental results show that with the addition of Span 20 and Span 80, the electrode wear ratio was decreased with the increased of surfactants weight percentage. Surface finish also can be improved by adding surfactant in the dielectric fluid. The lowest surface roughness was achieved at a surfactant weight percentage of 0.4wt%. The optimum weight percentage for obtaining the highest material removal rate (MRR) was 0.6wt% for both surfactants. In comparison, CNF added with surfactant Span 80 was more effective to improve the machining efficiency of RB-SiC compared to surfactant Span 20, at the optimum weight percentage 0.6wt%.

Optimization by Grey Relational Analysis of EDM Parameters on Machining Ti-6Al-4V

2010 ◽  
Vol 139-141 ◽  
pp. 540-544 ◽  
Author(s):  
Zhi Ping Xie ◽  
Ji Ming Zheng ◽  
Bian Li Quan
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Grey Relational Analysis ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Relational Analysis ◽  
Wear Ratio ◽  
Grey Relational

In this paper, parameter optimization of the electrical discharge machining process to Ti–6Al–4V alloy considering the multiple responses using the Taguchi method and grey relational analysis is reported. The multi-response optimization of the process parameters are material removal rate (MRR) and electrode wear rate (EWR). The machining parameters including discharge current, voltage, pulse on time and duty factor. Experiment based on the orthogonal array, The optimized process parameters simultaneously leading to a lower electrode wear ratio and higher material removal rate are then verified through a confirmation experiment. The experimental result for the optimal setting shows that there is considerable improvement in the process. The validation experiments show an improved electrode wear ratio of 2.8%, material removal rate of 45.8% when the Taguchi method and grey relational analysis are used.

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