Electro-Discharge Machining of Ceramics: A Review

Bilal, Azat; Jahan, Muhammad P.; Talamona, Didier; Perveen, Asma

doi:10.3390/mi10010010

Cited by 96 publications

(45 citation statements)

References 173 publications

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“…In recent years, rapid developments in aerospace, medical instruments, transportation, and many other industrial sectors increased the need for new materials with favorable characteristics. In addition to unique characteristics, most modern materials need special manufacturing processes to enable them to be machined with ease [1,2]. Most of these materials are usually difficult to cut by conventional manufacturing processes [3][4][5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with regard to selection of the process, material, and operating parameters, the effect on responses, various process variants, and new techniques adopted to enhance process performance. This paper reviews research studies on the EDM of different grades of tool steel materials. This article (i) pans out the reported literature in a modular manner with a focus on experimental and theoretical studies aimed at improving process performance, including material removal rate, surface quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used to determine process conditions, and (iii) discusses the developments in EDM and outlines the trends for future research. The conclusion section of the article carves out precise highlights and gaps from each section, thus making the article easy to navigate and extremely useful to the related research community.

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Section: Introductionmentioning

confidence: 99%

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

et al. 2020

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“…Depending on the frequency, this process can happen several to hundreds of times in a second, thus creating multiple overlapping craters. Although the EDM process is a combination of different phenomena, such as dielectric break down, plasma formation, heat conduction, fluid dynamics, electrical phenomenon, chemical phenomenon, etc., thermal effects with a small error can be considered as the dominating phenomenon in the EDM process [1][2][3][4][5].…”

Section: Introductionmentioning

confidence: 99%

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

et al. 2019

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This study reports on the numerical model development for the prediction of the material removal rate and surface roughness generated during electrical discharge machining (EDM). A simplified 2D numerical heat conduction equation along with additional assumptions, such as heat effect from previously generated crater on a subsequent crater and instantaneous evaporation of the workpiece, are considered. For the material removal rate, an axisymmetric rectangular domain was utilized, while for the surface roughness, a rectangular domain where every discharge resides at the end of previous crater was considered. Simulated results obtained by solving the heat equation based on a finite element scheme suggested that results are more realistic by considering instantaneous evaporation of the material from the workpiece and the effect of residual heat generated from each spark. Good agreement between our model and previously published data validated the newly proposed models and demonstrate that instantaneous evaporation, as well as residual heat, provide more realistic predictions of the EDM process. Machines 2019, 7, 47 2 of 17 model where the problem of heat conduction for both infinite and semi-infinite bodies with a constant heat source was solved. DiBitonto et al. [7] developed a point heat source cathode erosion model. Since spherical symmetry was considered in their model, the heat transfer equation in spherical coordinates was implemented. In their model, the constant cathode energy fraction of 0.183 was assumed. In their subsequent study [8], they developed an anode erosion model, by assuming a disk heat source. Beck et al.[9] developed a model to find the temperature distribution of a semi-infinite cylinder with a constant heat source and an insulated boundary. Since this model was not developed particularly for the EDM process, the heat fraction to the workpiece is not considered.Process performances of EDM have been investigated by many researchers. D'Urso et al.[10] defined a process index based on process parameters and material properties to analyze the process and geometric indexes of micro-EDM process. D'Urso and Ravasio [11], based on a material-technology index (MTI), studied the process performance of micro-EDM. Tsai and Masuzawa [12] analyzed the electrode wear of different electrode materials in a micro-EDM process. Based on experimental results, a new wear resistance index based on modified boiling and melting points for the evaluation of erosion performance was proposed. Marafona and Araujo [13] proposed an additive model to investigate the influence of hardness on the material removal rate and surface roughness. Alshemary et al. [14] studied effects of different process parameters on fabricating cylindrical holes by wire-EDM. Mandal et al. [15] investigated the surface integrity of wire-EDM. They reported that both grinding and etching-grinding techniques removed the recast layer, and hence improved the surface integrity. Prakash et al. [16] proposed altering the EDM process for coating TiO 2 -T...

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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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Electro-Discharge Machining of Ceramics: A Review

Cited by 96 publications

References 173 publications

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

Principles and Characteristics of Different EDM Processes in Machining Tool and Die Steels

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

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

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