The Electrical Discharge Machining (EDM) behaviour and machining properties of advanced engineering Si3N4-based ceramic composites Si3N4-TiN are investigated and discussed in this paper. Two types of EDM machining configurations, micro-EDM milling and die-sinking EDM, are employed in the investigation. Relaxation type of pulse is used, and the performances of EDM process in the form of material removal rate, tool wear and surface quality are studied. These tests result in a performance comparison and a discussion on the ceramic composites material removal mechanism. The feature of material removal mechanism is characterised as chemical decomposition of Si3N4 and TiN at elevated temperature rather than melting/evaporation. The generation of nitrogen gas bubbles leads to a porous and foamy top surface structure. Due to the ideal mechanical and physical property of Si3N4-TiN ceramic composites, an application example -a turbine impelleras a crucial component in a micro power generation system is manufactured with obtained knowledge in both machining configurations.
The paper presents the results of physical and mechanical properties of the and Si3N4 and SiC matrix ceramics with additives of good electrical conductivity carbides, nitrides and borides phases. The density, Young’s modulus, hardness HV1 and electrical conductivity of each material were investigated. Ceramic composite materials with the participation of the conductive phases have been produced using SPS (spark plasma sintering) method. Materials characterized by good electrical conductivity were shaped using EDM (electro discharge machining) method.
This paper presents the results of the processes of treating aluminum matrix casting materials with the addition of a ceramic phase. The matrix of the composite material was an Al-Si7 casting alloy with addition of 2 mass% Mg. The volume fraction of the reinforcing phase in the form of silicon carbide ranged from 5 to 15 vol.%. Preliminary machining tests were carried out at the Mori Seiki NL2000SY turning and milling center. The cutting properties were evaluated during longitudinal turning. Cutting tests were carried out using tools made of polycrystalline diamond, regular boron nitride, and cemented carbides. The nature of VBB wear was checked in accordance with PN-ISO 3685:1996. The influence of machining parameters (cutting speed, feed, cutting depth) on the value of cutting tools temperature was determined. An analysis of the chip shaping mechanism during machining was performed at various cutting parameters. The tests were carried out using the FLIR A655 thermal imaging camera and the fast Phantom MIRO M310 fast camera. Cast composite materials were also subjected to the processes of waterjet cutting, EDM cutting, and EDM drilling (EDM electro discharge machining).
Presented are the analysis of physical and mechanical properties of the Al2O3, SiC and Si3N4 matrix ceramics with additives of good electrical conductivity phases and TiB2 matrix ceramics. The density, Young’s modulus, hardness HV1 and electrical conductivity of each material were investigated. Ceramic composite materials with the participation of the conductive phases have been produced using SPS (spark plasma sintering) method. Materials characterized by good electrical conductivity were shaped using EDM (electro discharge machining) method.
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