Investigation on machining performance of micro-holes EDM in ZrB2-SiC ceramics using a magnetic suspension spindle system

Feng, Yu; Guo, Yanning; Ling, Zebin; Zhang, Xiaoyou

doi:10.1007/s00170-018-3116-1

Cited by 20 publications

(4 citation statements)

References 26 publications

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“…The developed method can supplement or even replace the existing monitoring methods of electrical parameters and contribute to the creation of a multi-factor adaptive control system. It can lead to the formation of a new vision and approach in the development of a new generation of CNC systems [74, 83, 228, 229].…”

Section: Discussionmentioning

confidence: 99%

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Grigoriev

Kozochkin

Porvatov

et al. 2019

Heliyon

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The productivity of electrical discharge machining (EDM) is relatively low owing to the natural laws of electrical erosion. Precise EDM demands uninterrupted control of the discharge gap and adjustment of process parameters. It is particularly critical for processing large workpieces with complex linear surfaces and for materials with threshold conductivities such as the new advanced ceramic nanocomposites Al2O3+TiC and Al2O3+SiCw+TiC(30–40%). In these cases, adequate flushing of erosion products is hampered by the geometry of the working space or by the small value of the required discharge gap, which does not exceed 2.2–2.5 μm. The methods of adaptive control in modern computer numerical control systems of EDM equipment based on measuring the electrical parameters in the working zone have been shown to be ineffective in the cases described above. This study aims to investigate the natural phenomena of material sublimation under discharge pulses for conductive ceramics and nanocomposites. The measured conductivities of the samples are higher than the percolation threshold. However, the question of machinability remains open owing to detected processing interruptions and poor quality of machined surfaces. New knowledge on EDM of conductive ceramics and nanocomposites can improve the final quality of the machined surfaces and productivity of the method by the introduction of advanced monitoring and control methods based on acoustic emissions. The manuscript presents an up-to-date overview and current state of the research on the subject area. The obtained morphology of the samples and discussion of the findings complete the experimental part of the study. The scientific basis for a new type of adaptive control system is provided. This can improve the effectiveness of parameter control for machining conductive ceramics and nanocomposites and contribute to an increase in the EDM performance for the most critical cases.

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Section: Discussionmentioning

confidence: 99%

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Grigoriev

Kozochkin

Porvatov

et al. 2019

Heliyon

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show abstract

“…Among various types of ceramics, ZrB2 ceramics are a better choice for the matrix part of bionic layered graphene ceramic matrix composites due to its low density, high melting point, high strength, high thermal conductivity and strong corrosion resistance [1][2][3][4][5] . The main problem with ZrB2 ceramics is its low fracture toughness [6] , which limits its applicability in the presence of thermal shock and vibration [7] .…”

Section: Introductionmentioning

confidence: 99%

Study on grinding removal mechanism and subsurface damage of bionic layered graphene ceramic matrix composites

Zhou,

Zou,

Zhang

et al. 2024

Int J Adv Manuf Technol

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Bionic layered graphene ceramic matrix composites have excellent properties of high strength, high toughness and heat resistance, and are important materials for national defense equipment, but they are also typical brittle and difficult-to-machine materials. To achieve high quality and low damage machining of the composite parts, grinding removal mechanism and subsurface damage are investigated in this paper. Firstly, the SPH simulation models for indentation and scratching of a single diamond grain are established. The effect of addition of graphene nanosheets on the crack expansion mechanism and subsurface damage is investigated. Then, the simulation models of different angles of graphene nanosheets are established to analyze the effect of graphene anisotropy on grinding process of composites. Finally, the grinding removal mechanism of the composites is investigated by analysing crack expansion and removal forms of the composites at different scratching velocities and depths. The results show that incorporation of graphene nanosheets can reduce subsurface damage of composites and provide a certain shielding effect on the cracks. The optimal effects for reducing subsurface damage and cracks are obtained when graphene nanosheets angle is 0°. As scratching depth increases, the material removal mode gradually changes from plastic removal to brittle removal, and subsurface damage and crack depths also increases. The increase in scratching velocity leads to a subsequent increase in material strain rate, which inhibits crack generation and reduces subsurface damage depth. The form of material removal and crack generation in scratching experiments is consistent with the simulation analysis when changing the scratching depth.Furthermore, the effect of graphene nanosheets on crack deflection corresponds with the simulation results. This study can provide an important theoretical basis for the grinding process of bionic layered graphene ceramic matrix composite parts.

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“…Yerui Feng et al proposed a high response frequency magnetic levitation spindle system (MSSS) EDM technique for high-precision micro-hole machining of zirconium diboride-silicon carbide (ZrB-SiC) ceramics and superalloy Inconel 718, and the experimental results showed that MSSSEDM has higher e ciency and quality compared with conventional EDM [11][12] . Dong Yinghuai et al designed a small ultrasonic vibration-assisted EDM machine tool to avoid spark concentration and abnormal arcing during machining [13] .…”

Section: Introductionmentioning

confidence: 99%

Experimental study of EDM characteristics using a 5-DOF controllable magnetic levitation actuator

Luan

Zhang²,

Xu³

et al. 2022

Int J Adv Manuf Technol

Self Cite

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The e ciency and accuracy of conventional electrical discharge machining (EDM) is limited by the stability of the voltage between the poles. To improve the e ciency of EDM, this paper proposes a machining method that combines a self-developed 5-degree-of-freedom (5-DOF) controllable magnetic levitation actuator with a conventional EDM machine tool. The stability of the inter-pole voltage is improved by the actuator micro-adjustment the electrodes of the EDM machine tool. Firstly, an EDM control system with local current feedback and decoupling control elements is designed based on the EDM servo drive principle to improve the response speed and positioning accuracy of the actuator. Secondly, the actuator was connected to the spindle of a conventional EDM machine tool, and machining experiments were carried out. The experimental results showed that the EDM machine tool connected to the actuator could control the electrode position more quickly, adjust the discharge state quickly, and increase the number of discharges per unit time. The average machining speed increased from 1.108µm/s to 3.925µm/s, which is 3.54 times faster than conventional EDM. Finally, complex shape machining experiments were carried out and the machining results showed that by adjusting the target value of the radial direction of the actuator, the various trajectories of the electrode could be controlled to depict arbitrary shapes.

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Investigation on machining performance of micro-holes EDM in ZrB2-SiC ceramics using a magnetic suspension spindle system

Cited by 20 publications

References 26 publications

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

Study on grinding removal mechanism and subsurface damage of bionic layered graphene ceramic matrix composites

Experimental study of EDM characteristics using a 5-DOF controllable magnetic levitation actuator

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