Experimental research on electrical discharge machining characteristics of engineering ceramics with different electrical resistivities

Ji, Renjie; Y, Liu; Diao, Ruiqiang; Zhang, Yanzhen; Wang, Fei; Cai, Baoping; Xu, Chenchen

doi:10.1007/s00170-014-6258-9

Cited by 16 publications

(5 citation statements)

References 16 publications

(15 reference statements)

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“…Lots of researchers have tried to explore the wear law of tool electrode by studying the influences of current, electrical resistivity, pulse duration, hole depth, and tool electrode material on the characteristics of tool electrode wear [10][11][12]. Since the ejectment of debris particles becomes more difficult as the machining depth increases, the tool wear rate increases independent of voltage and workpiece [13].…”

Section: Introductionmentioning

confidence: 98%

Effect of Electrode Size on the Performances of Micro-EDM

Liu

Zhang

Zhu

et al. 2015

Materials and Manufacturing Processes

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Understanding the effect of processing parameters on the tool electrode wear during micro electrical discharge machining (Micro EDM) is helpful to predict and compensate the electrode wear, so as to improve the machining precision. In this paper, experiments are carried out and the influences of tool electrode diameter on the micro EDM process are discussed based on the skin effect and area effect. It is demonstrated that the machining speed, tool wear and taper rate are different with the increase of tool electrode diameter. Due to the skin effect and area effect, larger electrode diameter results in higher material removal rate along with higher tool wear rate. The electrode material removal increment is more than the workpiece material removal increment with the increase of tool electrode diameter, which leads to the increase of relative tool wear ratio. Discharge energy is concentrated on the tool surface which enhances the possibility of discharge on the side face and the corner of the tool electrode during the micro EDM, especially when drilling with a larger tool electrode. As a result, a tool electrode with larger diameter results in a higher taper rate.

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Section: Introductionmentioning

confidence: 98%

Effect of Electrode Size on the Performances of Micro-EDM

Liu

Zhang

Zhu

et al. 2015

Materials and Manufacturing Processes

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“…At present, the special micro-hole machining methods available for engineering ceramics include laser machining, 2,3 ultrasonic machining 4,5 and electrical discharge machining (EDM). 6,7 However, they have several shortcomings such as low machining efficiency and high cost. Laser microfabrication experiments on glass, silicon and ceramics by Rihakova and Chmelickova 2 disclosed that the ultrafast laser can achieve better processing quality.…”

Section: Introductionmentioning

confidence: 99%

“…The effects of different abrasive grit sizes (120, 220 and 400) on material removal rate, surface integrity and flexural strength were presented. The effects of EDM parameters (pulse on-time, pulse off-time and peak current) and electrical resistivity on EDM performance of ZnO/ Al 2 O 3 ceramics were studied by Ji et al 6 The results showed that the electrical resistivity of ZnO/Al 2 O 3 ceramics, which could be effectively machined by EDM, increased with the increase in pulse on-time and peak current and with the decrease in pulse off-time.…”

Section: Introductionmentioning

confidence: 99%

Study on hole machining for the constant feed rate of Al₂O₃ engineering ceramics through low-frequency axial vibration

Liu

Zhang

Dong

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Engineering ceramics are increasingly extensively applied in the aerospace, vehicle, armor protection and other fields due to their excellent performances such as high compression strength, high hardness, low density and high protection performance. However, engineering ceramics are typical difficult-to-machine materials, especially in the hole machining under constant feed rate, which limits the promotion and application. In this study, by combining a specially developed novel thin-wall diamond trepanning bit with a low-frequency axial vibration machining, the hole machining process for the constant feed rate of Al2O3 engineering ceramics was experimentally studied and the influence of the low-frequency axial vibration process on the axial drilling force, hole-wall surface roughness and edge chipping size of holes machined was analyzed. The results showed that the low-frequency axial vibration machining obtained a lower axial drilling force and a smaller edge chipping size compared to the traditional drilling process. Moreover, both the axial drilling force and the edge chipping size declined markedly with the rise in amplitude. However, the hole-wall surface roughness presented a rising trend due to the hammering effect of vibration. The process technology proposed in this article realizes the hole machining for a constant feed rate of Al2O3 engineering ceramics and provides a reference for the engineering lot-size hole machining of engineering ceramics.

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“…Micro holes or linear grooves which are straight or inclined on cemented carbide cutting tool rake face or on scrap reeling slot can be obtained conveniently using proper micro tool electrodes and appropriate pulse parameters [22]. Lasting electro-discharge conditions between the micro tool electrode and cemented carbide materials can be improved by high-frequency vibration.…”

Section: Introductionmentioning

confidence: 99%

Surface textures on cemented carbide cutting tools by micro EDM assisted with high-frequency vibration

Deng

Chai

et al. 2015

Int J Adv Manuf Technol

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This paper demonstrates the process of micro electro-discharge machining (micro EDM) assisted with high-frequency vibration machining micro holes and linear grooves which are straight or inclined on WC/8 % Co (MA) and WC/15 % TiC/6 %Co (MB) cemented carbide cutting tool rake face or scrap reeling slot. Low-voltage sensing contact is introduced to determine the exact position of holes and grooves. Morphology of textured regions is examined and the elemental chemical composition of close proximity region to a straight hole is identified. Results show that micro holes and linear grooves with high dimension accuracy and exact position are machined as expected by micro EDM assisted with high-frequency vibration. There is no debris accumulating around the cavities. Materials of MA cutting tool adhere on the micro tool electrode slightly, while the dimension of adhesion position becomes constant after 3 μ holes are finished. However, the adhesion does not occur during machining MB cutting tools. The distance of edges of grain refinement regions and areas where elemental chemical composition varies to the contour of the hole is no more than 15 μm.

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Experimental research on electrical discharge machining characteristics of engineering ceramics with different electrical resistivities

Cited by 16 publications

References 16 publications

Effect of Electrode Size on the Performances of Micro-EDM

Effect of Electrode Size on the Performances of Micro-EDM

Study on hole machining for the constant feed rate of Al₂O₃ engineering ceramics through low-frequency axial vibration

Surface textures on cemented carbide cutting tools by micro EDM assisted with high-frequency vibration

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Experimental research on electrical discharge machining characteristics of engineering ceramics with different electrical resistivities

Cited by 16 publications

References 16 publications

Effect of Electrode Size on the Performances of Micro-EDM

Effect of Electrode Size on the Performances of Micro-EDM

Study on hole machining for the constant feed rate of Al2O3 engineering ceramics through low-frequency axial vibration

Surface textures on cemented carbide cutting tools by micro EDM assisted with high-frequency vibration

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Product

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Study on hole machining for the constant feed rate of Al₂O₃ engineering ceramics through low-frequency axial vibration