A comprehensive review of electric discharge machining of advanced ceramics

Ming, Wuyi; Jia, Haojie; Zhang, Hongmei; Zhang, Zhen; Liu, Kun; Du, Jinguang; Shen, Fan; Zhang, Guojun

doi:10.1016/j.ceramint.2020.05.207

Cited by 84 publications

(17 citation statements)

References 116 publications

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“…This is consistent with the perspective in Ref. [32]. In addition, the influence of the direct sublimating of the aluminum matrix from a solid to a gas (thermal dissociation), the thermochemical interaction between ions and the deposition of more-complex secondary compounds of the second order may also contribute to the method of removal of SiCp/Al in EDM/WEDM [33].…”

Section: Machined Surface Characteristicssupporting

confidence: 88%

Analysis and Optimization of the Machining Characteristics of High-Volume Content SiCp/Al Composite in Wire Electrical Discharge Machining

et al. 2021

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With the properties of high specific strength, small thermal expansion and good abrasive resistance, the particle-reinforced aluminum matrix composite is widely used in the fields of aerospace, automobile and electronic communications, etc. However, the cutting performance of the particle-reinforced aluminum matrix composite is very poor due to severe tool wear and low machining efficiency. Wire electrical discharge machining has been proven to be a good machining method for conductive material with any hardness. Even so, the high-volume SiCp/Al content composite is still a difficult-to-machine material in wire electrical discharge machining due to the influence of insulative the SiC particle. The goal of this paper is to analyze the machining characteristics and find the optimal process parameters for the high-volume content (65 vol.%) SiCp/Al composite in wire electrical discharge machining. Experimental results show that the material removal method of the SiCp/Al composite includes sublimating, decomposing and particle shedding. The material removal rate is found to increase with the increasing pulse-on time, first increasing and then decreasing with the increasing pulse-off time, servo voltage, wire feed and wire tension. Pulse-on time and servo voltage are the dominant factors for surface roughness. In addition, the multi-objective optimization method of the nondominated neighbor immune algorithm is presented to optimize the process parameters for a fast material removal rate and low surface roughness. The optimized process parameters can increase the material removal rate by 34% and reduce the surface roughness by 6%. Furthermore, the effectiveness of the Pareto optimal solution is proven by the verified experiment.

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Section: Machined Surface Characteristicssupporting

confidence: 88%

Analysis and Optimization of the Machining Characteristics of High-Volume Content SiCp/Al Composite in Wire Electrical Discharge Machining

et al. 2021

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“…According to the existing literatures, it is feasible for EDM to cut a hydrophobic micro-structured surface, such as grooves, micro/nano structure, and hydrophobic meshes; the processing steps of EDM are few and it is convenient for large-scale industrial applications in the future. Generally speaking, the machining quality (precision and surface quality) of EDM is in conflict with the material removal rate (MRR) [ 33 , 34 , 35 ]. Therefore, under the premise of ensuring that the hydrophobic micro-structured surface can be completed, it is necessary to study the improvement of MRR and optimize its machining performances to further reduce the cost of large-scale manufacturing in the future.…”

Section: Electrical Discharge Machiningmentioning

confidence: 99%

“…However, non-conductive materials (glass and non-conductive ceramic materials) are also very popular in industrial applications. Therefore, in the future, methods such as auxiliary electrode EDM or high-voltage discharge EDM could be used to solve this problem [ 34 , 36 , 37 ].…”

Section: Electrical Discharge Machiningmentioning

confidence: 99%

Progress in Non-Traditional Processing for Fabricating Superhydrophobic Surfaces

Shen¹,

Ming

Ren

et al. 2021

Micromachines

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When the water droplets are on some superhydrophobic surfaces, the surface only needs to be inclined at a very small angle to make the water droplets roll off. Hence, building a superhydrophobic surface on the material substrate, especially the metal substrate, can effectively alleviate the problems of its inability to resist corrosion and easy icing during use, and it can also give it special functions such as self-cleaning, lubrication, and drag reduction. Therefore, this study reviews and summarizes the development trends in the fabrication of superhydrophobic surface materials by non-traditional processing techniques. First, the principle of the superhydrophobic surfaces fabricated by laser beam machining (LBM) is introduced, and the machining performances of the LBM process, such as femtosecond laser, picosecond laser, and nanosecond laser, for fabricating the surfaces are compared and summarized. Second, the principle and the machining performances of the electrical discharge machining (EDM), for fabricating the superhydrophobic surfaces, are reviewed and compared, respectively. Third, the machining performances to fabricate the superhydrophobic surfaces by the electrochemical machining (ECM), including electrochemical oxidation process and electrochemical reduction process, are reviewed and grouped by materials fabricated. Lastly, other non-traditional machining processes for fabricating superhydrophobic surfaces, such as ultrasonic machining (USM), water jet machining (WJM), and plasma spraying machining (PSM), are compared and summarized. Moreover, the advantage and disadvantage of the above mentioned non-traditional machining processes are discussed. Thereafter, the prospect of non-traditional machining for fabricating the desired superhydrophobic surfaces is proposed.

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“…Prakash et al [21] studied the surface modification of Ti-6Al-4V alloy partial sintered Ti-Nb electrode discharge coating. Moreover, our team studied [22,23] the process optimization of the magnetic field-assisted electric discharge machining method, including not only the electrical parameters, but also the magnetic field strength. In addition, with the development of advanced ceramic materials, EDM also needs to consider its economics and needs to optimize its machining process [24].…”

Section: Introductionmentioning

confidence: 99%

A Cuckoo Search Algorithm Using Improved Beta Distributing and Its Application in the Process of EDM

Shen¹,

Ming

Ren

et al. 2021

Crystals

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Lévy flights random walk is one of key parts in the cuckoo search (CS) algorithm to update individuals. The standard CS algorithm adopts the constant scale factor for this random walk. This paper proposed an improved beta distribution cuckoo search (IBCS) for this factor in the CS algorithm. In terms of local characteristics, the proposed algorithm makes the scale factor of the step size in Lévy flights showing beta distribution in the evolutionary process. In terms of the overall situation, the scale factor shows the exponential decay trend in the process. The proposed algorithm makes full use of the advantages of the two improvement strategies. The test results show that the proposed strategy is better than the standard CS algorithm or others improved by a single improvement strategy, such as improved CS (ICS) and beta distribution CS (BCS). For the six benchmark test functions of 30 dimensions, the average rankings of the CS, ICS, BCS, and IBCS algorithms are 3.67, 2.67, 1.5, and 1.17, respectively. For the six benchmark test functions of 50 dimensions, moreover, the average rankings of the CS, ICS, BCS, and IBCS algorithms are 2.83, 2.5, 1.67, and 1.0, respectively. Confirmed by our case study, the performance of the ABCS algorithm was better than that of standard CS, ICS or BCS algorithms in the process of EDM. For example, under the single-objective optimization convergence of MRR, the iteration number (13 iterations) of the CS algorithm for the input process parameters, such as discharge current, pulse-on time, pulse-off time, and servo voltage, was twice that (6 iterations) of the IBCS algorithm. Similar, the iteration number (17 iterations) of BCS algorithm for these parameters was twice that (8 iterations) of the IBCS algorithm under the single-objective optimization convergence of Ra. Therefore, it strengthens the CS algorithm’s accuracy and convergence speed.

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A comprehensive review of electric discharge machining of advanced ceramics

Cited by 84 publications

References 116 publications

Analysis and Optimization of the Machining Characteristics of High-Volume Content SiCp/Al Composite in Wire Electrical Discharge Machining

Analysis and Optimization of the Machining Characteristics of High-Volume Content SiCp/Al Composite in Wire Electrical Discharge Machining

Progress in Non-Traditional Processing for Fabricating Superhydrophobic Surfaces

A Cuckoo Search Algorithm Using Improved Beta Distributing and Its Application in the Process of EDM

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