Investigation of surface roughness in micro-electro discharge machining of nonconductive ZrO<sub>2</sub> for MEMS application

Sabur, Abdus; Moudood, Abdul; Ali, Mohammad Yeakub; Maleque, Abdul

doi:10.1088/1757-899x/53/1/012090

Cited by 6 publications

(8 citation statements)

References 5 publications

(1 reference statement)

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“…In the present work, Taguchi's L9 orthogonal array was used to organize the input parameters (voltage, pulse duration, and tool speed) and their levels . The input parameters and their levels were selected based on the work reported in the area of EDM of nonconductive materials . Each set of experiment was repeated at least three times to nullify any random variation in the experimental data.…”

Section: Methodsmentioning

confidence: 99%

“…The major advantages of DESSEDG were high efficiency, low processing cost, environment friendliness, and so on. Sabur et al performed μEDM process for making blind holes on nonconductive zirconia for microelectromechanical (MEMS) application. A layer of copper sheet having conductive adhesive was applied over the work surface to initiate the spark.…”

Section: Literature Surveymentioning

confidence: 99%

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A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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This article presents micro electrical discharge machining (μEDM) of carbon fiber‐reinforced plastics (CFRP) with rotating tool electrode and assisting electrode (AE). The experimental investigation majorly focused on establishing the mechanisms of material removal and surface integrity of the machined blind holes. Taguchi and regression analysis were carried out to assess the material removal rate (MRR). Analysis of variance (ANOVA) was applied to understand the significance of input parameters and their contribution toward achieving maximum MRR. The surface integrity of the machined hole and damage modes of composite constituents were also examined through micrographic images. The experiments were carried out varying the voltage, pulse duration, and tool speed at three levels. The investigations showed that μEDM process can be applied for fabricating micro holes in CFRP if assisting electrode (AE) is used to initiate the spark. From the analysis of variance (ANOVA), it was observed that the percentage contribution of voltage, pulse duration, and tool rotational speed on MRR are 75.09, 5.20, and 16.09%, respectively. The optimal condition for the highest MRR was found to be V3/T1/S3 (voltage of 170 V, pulse duration of 10 μs, and tool speed of 800 rpm). The calculated value of MRR (341,264.94 μm3/s) at the optimum level of input parameters was found to be close to the experimental MRR (340,727 μm3/s). The percentage error between the experimental and calculated value of MRR at the optimum level is very low as 0.15%. This indicates that the developed statistical model is quite significant in predicting MRR during μEDM of CFRP. POLYM. COMPOS., 40:4033–4041, 2019. © 2019 Society of Plastics Engineers

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Section: Methodsmentioning

confidence: 99%

Section: Literature Surveymentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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“…light interferometry. The power settings of the micro-EDM process were gradually increased to obtain surfaces with increasing roughness [30]. The R a (R z ) values increased from 5.1±1.0 nm (0.1±0.1 μm) for untreated electrodes to 198.3±19.1 nm (2.2±0.2 μm), 347.6±15.5 nm (3.3±0.2 μm) and 681.6±127.8 nm (5.3±0.7 μm) for treated electrodes with low, medium and high roughness machining settings, respectively.…”

Section: Electrode Surface Modification and Characterizationmentioning

confidence: 99%

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

Pierra

Golozar

Zhang

et al. 2018

Bioelectrochemistry

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Bioelectrochemical systems couple electricity demand/supply to the metabolic redox reactions of microorganisms. Generally, electrodes act not only as electron acceptors/donors, but also as physical support for an electroactive biofilm. The microorganism-electrode interface can be modified by changing the chemical and/or topographical features of the electrode surface. Thus far, studies have reported conflicting results on the impact of the electrode surface roughness on the growth and current production of biofilms. Here, the surface roughness of the glassy carbon electrodes was successfully modified at the sub-microscale using micro electrodischarge machining, while preserving the surface chemistry of the parent glassy carbon. All microbial electrodes showed similar startup time, maximum current density, charge transport ability across the biofilm and biomass production. Interestingly, an increase in the average surface cavity depth was observed for the biofilm top layer as a function of the electrode surface roughness (from 7 μm to 16 μm for a surface roughness of 5 nm to 682 nm, respectively). These results indicated that the surface roughness at a sub-microscale does not significantly impact the attachment or current production of mixed culture anodic biofilms on glassy carbon. Likely earlier observations were associated with changes in surface chemistry, rather than surface topography.

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“…However, when machining ceramics, the increase has its limit to allow the formation of a carbon layer under the given machining conditions. According to sources from the literature, when machining ceramics, the duty factor ranges from 20 ÷ 50% [11,12]. When machining with higher discharge currents and pulse duration, it is desirable that this coefficient moves to lower values.…”

Section: Fig 2 Edm Machine Agie Charmilles Of the Sp1-u Typementioning

confidence: 99%

Untitled

2022

J. Prod. Eng.

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Electrical discharge machining (EDM) is an unconventional machining process that can machine all electrically conductive materials, regardless of their physical and metallurgical properties. Due to the efficiency of machining modern engineering materials, existing EDM methods are constantly being researched and improved or developed. This paper deals with an innovative method that enables EDM machining of non-conductive ceramic material, named Assisting Electrode Electrical Discharge Machining (AEEDM). It combines electrical discharge machining with a hybrid assisting electrode. The aim of the study is to find the influence of pulse duration on surface roughness. For the set machining conditions, it was found that the surface roughness was increased by increasing the pulse duration. It should be emphasized that the supporting electrode method is used only in the electroerosion of electrically non-conductive materials.

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Investigation of surface roughness in micro-electro discharge machining of nonconductive ZrO₂ for MEMS application

Cited by 6 publications

References 5 publications

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

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Investigation of surface roughness in micro-electro discharge machining of nonconductive ZrO2 for MEMS application

Cited by 6 publications

References 5 publications

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

Growth and current production of mixed culture anodic biofilms remain unaffected by sub-microscale surface roughness

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Investigation of surface roughness in micro-electro discharge machining of nonconductive ZrO₂ for MEMS application