Surface morphology and drilled hole accuracy of conductive ceramic composites Si 3 N 4 -TiN and MoSi 2 -SiC on EDMed surfaces

Abstract

By using electro-discharge machining (EDM), conductive ceramic composites made of Silicon Nitride and Titanium Nitride (Si3N4-TiN) and intermetallic ceramic composite (MoSi2-SiC) were machined while performance metrics of crucial importance to the EDM process were measured. The two conductive ceramic composites are thoroughly examined using machining parameters including current, spark on time, spark off time, and dielectric pressure. For multiple responses of geometrical errors, such as circularity, cylindricity, and perpendicularity, as well as performance metrics like metal removal rate (MRR), electrode wear rate (EWR), wear ratio, and surface integrity on the machined surface of the workpiece and electrode. Taguchi’s based L9 Orthogonal array (OA) based onthe design of experiments(DOE) is used to carry out the experimental runs to identify the optimum parameters of Si3N4–TiN and MoSi2–SiC ceramic composite. By analyzing the performance of conductive ceramic composites, the optimized results achieved from these approaches are suggested to improve themetal removal rate and lower the tool wear ratio, surface roughness and geometrical tolerances. An elaborated investigation of material removal mechanism and the surface topographyas examined by the SEM instrument with EDAX report in the machined surface for both composites. By analysing the machined surface on the best hole with the best electrode and the worst hole with the worst electrode the surface textures from nine holes and electrodes for ceramic composites are studied. Thus, simultaneously analysed and established EDM process appears to be a promising method for producing excellent surfacesin anelectrically conductive Si3N4–TiN and MoSi2–SiC composite under slow process parameters condition of conductive ceramic composites.

Investigation into Optimizing of Machining Parameters using RSM for Si3N4 -TiN Ceramic C omposites by WEDM

“…When compared to using a plain brass wire electrode for Si 3 N 4 -TiN composite, an increase in cutting rates of 4.39% is observed at minimum values of pulse duration and current, while an increment of 16.67% is noted when the pulse duration and current were at maximum values (20) . The emphasis of the current work is on achieving a notable cutting rate, as demonstrated by the experimental data, suggesting that zinc-coated brass electrode is a viable substitute for the molybdenum electrode used by Selvarajan et al (17) .…”

“…They are highly preferred in industries due to its performance and costing. (17) Several significant gaps persist, notably obtaining a more uniform, steeper width of cut, along with maximum cutting rates is a major challenge for researchers This needed to be addressed for the sake of dimensional accuracy, and sustainability of the product during manufacturing. Minimizing width of cut (Kerf) and maximizing cutting rates is a potential challenge before researchers for machining of ceramic composite, specially Si 3 N 4 -TiN composite.…”

Recent Research in Wire Cut Electrical Discharge Machining Process

“…Comparison is made between the two conductive ceramic composites' machining properties, which include current, spark on time, spark off time, and dielectric pressure. [2] XinyuYang et al, gave a presentation on the study of the core loss for amorphous alloys after wire-cut electric discharge machining, including the mechanism of degradation and high-precision modeling. Through an analysis of the domain width and nano-mechanical characteristics fluctuation in the magnetic domain distribution, this work suggests that the range of performance degradation for AA ribbons processed by W-EDM is within 1 mm of the edge.…”