Electro-discharge machining of alumina: Investigation of material removal rate and surface roughness

Ali, Mohammad Yeakub; Moudood, M. A.; Maleque, Abdul; Hazza, Muataz Hazza Faizi Al; Adesta, Erry Yulian Triblas

doi:10.15282/jmes.11.4.2017.5.0271

Cited by 6 publications

(5 citation statements)

References 23 publications

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“…Further, projected values are compared to experimental data, and deviation is computed as a percentage of error related to each performance feature, using the equation below. In reference [9], the authors found an MRR of 0.078 mm 3 /min and SR of 2.589 µm at adhesive copper (Cu) foil, 1.1 A peak current, 6 µs pulse-on time, and 14 V gap voltage in sinking EDM. In a method similar to this research, it was found that the use of adhesive copper (Cu), a smaller peak current, and the gap voltage achieved better SR.…”

Section: Confirming Resultsmentioning

confidence: 99%

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Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

Zeng

Lin

Dai³

et al. 2021

Processes

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The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.

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Section: Confirming Resultsmentioning

confidence: 99%

“…In contrast, EDM still has advantages in machining accuracy and material removal rate. Since EDM is a non-contact thermo-physical process, it is necessary to re-understand the EDM process and explore its adaptability to non-conductive materials that has become another research hotspot in the field of EDM [5][6][7][8][9].…”

Section: Introductionmentioning

confidence: 99%

Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

Zeng

Lin

Dai³

et al. 2021

Processes

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“…The analysis of the leading world scientific competitors in this domain shows that the world community is separated as it was mentioned above. One group of scientists is focused on the modification of nanoceramics with conductive inclusions to create systems such as ZrO 2 -Ta, ZrO 2 -TiC, ZrO 2 -TiCN, Si 3 N 4 -TiC, Si 3 N 4 -TiCN, Al 2 O 3 -TiC, Al 2 O 3 -TiCN [49][50][51][52][53][54][55][56][57][58][59], as well as inclusions based on graphene and oxide graphene and graphene nanotubes [23,[60][61][62][63][64]. Another group of scientists has focused their research on the processing capabilities of existed ceramics and non-conductive ceramic composites.…”

Section: The Main Scientific Competitorsmentioning

confidence: 99%

On Electrical Discharge Machining of Non-Conductive Ceramics: A Review

et al. 2019

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The inability of ceramic and nanoceramic processing without expensive diamond tools and with a high-material-removal rate hampers the scope of its potential applications and does not allow humanity to make a full shift to the sixth technological paradigm associated with Kuhn scientific revolutions and Kondratieff's waves and restrains the growth of the economy. The authors completed a review on the research state of ceramic and nanoceramic processing by electrical discharge machining, which is possibly solved by two principal approaches associated with the usage of standard commercially available machine tools. The first approach is related to the introduction of expensive secondary phase; the second approach proposes initiate processing by adding auxiliary electrodes in the form of coating, suspension, aerosol, or 3D-printed layer based on the components of silver, copper, or graphite in combination with an improved dielectric oil environment by introducing graphite or carbon nanoparticles, which is hugely relevant today.Technologies 2019, 7, 55 2 of 16 of cutting tools limits the resulting geometry of the product. Other machining methods such as vibroacoustic machining, laser and electron beam scribing, selective laser sintering with a binder, find their specific place in the processing of ceramics. However, they do not allow the receiving of all geometrically possible shapes of the product without losses on the operational parameters of ceramics [16][17][18].One of the most popular methods for the production of parts, regardless of their hardness, is electrical discharge machining (EDM). However, it requires the material to be conductive [19][20][21]. The process of electrical erosion of the material consists of initiating electric pulses in the interelectrode gap, in the breakdown of the dielectric medium in the gap, in establishing a discharge channel, where the temperature reaches more than 10,000 • C (low-temperature plasma). Due to such temperatures, the material is ablated, the drops of cooled material as eroded debris are washed away by the flow of the dielectric medium, and the electrodes again approach to resume the cycle. Thus, a unique crater-like topology on the surface of the workpiece is created [22][23][24][25].The inability of ceramics and nanoceramics to conduct current hampers the scope of its potential applications and restrains the growth of the progress and the switch to the next technological paradigm that most of the scientists associate with the term "nano" [26][27][28][29][30][31][32].Thus, it can be concluded that the study and development of a method for electrical discharge machining of non-conductive ceramics and nanoceramics are incredibly relevant today.The authors propose to apply the dialectical approach of cognition as a scientific approach to solve the formulated scientific problem. The dialectical approach includes the systematization and updating of existing knowledge and new data about the object of research.

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“…The Composite Desirability (D) value in this paper builds from the minimum values of these responses. Consequently, the function of D value is given by [33][34][35]: (14) where dn is the sub-desirability, Mn is the maximum boundary for the desired response, Rn is the desired response, Tn is the target for the desired response, w is the weight factor (w = 1), and m refers to the number of responses. In Figure 8, D value for TWR and q(r) depending on the Response Surface Methodology (RSM) is 96.76%.…”

Section: Influence Of the Spark Channel On The Tool Damagementioning

confidence: 99%

Influence of the spark heat on the electrode behavior in Powder Mixed-EDM environment

Abbas

Lajis

Jawad

et al. 2019

JMES

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Most past studies did not attempt to improve the numerical model for the electrode removal rate which depends on the experimental results. Furthermore, these studies have not included the damage-sensing for the electrode in Powder Mixed-EDM (PMEDM) medium. Therefore, the current study aims to enhance this model for the copper electrode based on the heat flux for the spark channel. Besides, it focuses on sensing the copper electrode damage depending on the slope relation between eroding velocity and the pulse duration. In both studies, during machining D2 steel, Nano chromium powder in the dielectric liquid is applied. The correlation factor between the Numerical Heat Flux q(r) and the experimental results for the Tool Wear Rate (TWR) attained is 93.06%. The value of this factor improves the mathematical model for TWR instead of the traditional mechanism that adopts the crater volume. Also, the damage-sensing constant (STD) in the copper electrode is very efficient at the minimum value of the peak current (IP), powder concentration (PC) and the maximum level of the pulse duration (Ton). Thus, the statistical confirmation using Response Surface Methodology (RSM) produced a higher value of the composite desirability (96.76%) and error percent equals to (10.3%-1.55%) and (0.18%-2.40%) for TWR and q(r), respectively. On the other hand, the optimum operation values are IP = 10 Amps, Ton = 30 µs, and PC = 2 g/L. These confirmation values are similar to the trials No. (3) and No. (11). Therefore, these values confirm the main purpose in order to obtain the best performance for TWR at the minimum spark heat. Keywords: D2 steel; Powder Mixed-EDM; electrode damage; heat flux of the spark channel.

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Electro-discharge machining of alumina: Investigation of material removal rate and surface roughness

Cited by 6 publications

References 23 publications

Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

On Electrical Discharge Machining of Non-Conductive Ceramics: A Review

Influence of the spark heat on the electrode behavior in Powder Mixed-EDM environment

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