Abstract
This research is aimed to describe a new approach for machining zirconia ceramics. The purpose is to develop an electrical discharge machining with assisting electrode and dielectric mixed with graphite powder to enable processing of nonconductive material and improve machining performance. Methodology that used in this paper is Box-Behnken design. Three controllable parameters were selected, namely discharge current, pulse duration, and graphite powder concentration. The material removal rate, surface roughness, and relative tool wear were chosen as machining performances. The proposed approach uses the concept of response surface methodology to develop mathematical models. Although the discharge current and pulse duration proved to be the most influential input parameters, the finding that resulted in this research is the positive effect of graphite powder on machining performance. The proposed approach provides a very beneficial option of EDM input parameters to achieve the performance improvement: increase in material removal rate, reduction in surface roughness and relative tool wear.
Highlights
Despite its exceptional properties compared to metallic materials, ceramics are gradually gaining acceptance in the manufacturing industry
It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder
The paper presents the results of an experimental investigation carried out with the aim of modelling the electrical discharge machining of non-conductive ceramic material
Summary
Despite its exceptional properties compared to metallic materials, ceramics are gradually gaining acceptance in the manufacturing industry. Various processes can be used to machine ceramic materials, such as diamond tool grinding, ultrasonic machining, laser machining, water abrasive machining, ion beam machining, etc. It is necessary to consider other methods by which ceramic materials can be machined. Electrical Discharge Machining (EDM) is a machining process that can process all electrically conductive materials, regardless of their physical and metallurgical properties [3]. To machine electrically nonconductive materials by EDM, electrical contact should be established [4]. This is solved by the method of assisting electrodes, which helps to start the discharge between tools and non-conductive materials. Discharges can continue if maintaining favorable conditions for the creation of a secondary electrically conductive layer [5]
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