Abstract
The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.
Highlights
Electrical discharge machining (EDM) mainly produces high-temperature melting and vaporization of materials through discharge between electrodes, so the machinability of materials mostly depends on the thermal properties of materials, such as melting point, specific heat, thermal conductivity, etc.; the mechanical properties of materials have little effect
When electrical discharge machining is in progress, apply a voltage of tens to hundreds of volts between the two poles, and use the servo control system to control the tiny gap between the two poles, so that the tool electrode slowly approaches the workpiece
When the gap between the two poles reaches the maximum at a small distance from μm to tens of μm, the free ions in the machining fluid will gather due to the action of the electric field, and they will be arranged into an ion-intensive current path, which promotes the insulation breakdown of the machining fluid between the two poles, forming a plasma channel; this is called the discharge phenomenon
Summary
Electrical discharge machining (EDM) mainly produces high-temperature melting and vaporization of materials through discharge between electrodes, so the machinability of materials mostly depends on the thermal properties of materials, such as melting point, specific heat, thermal conductivity, etc.; the mechanical properties of materials have little effect. The principle of electrical discharge machining is to use resistors and capacitors to form a charging and discharging circuit, and to place conductive tool electrodes and workpieces in an insulating machining fluid. When the gap between the two poles reaches the maximum at a small distance from μm to tens of μm, the free ions in the machining fluid will gather due to the action of the electric field, and they will be arranged into an ion-intensive current path, which promotes the insulation breakdown of the machining fluid between the two poles, forming a plasma channel; this is called the discharge phenomenon
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