Abstract
In this paper, the effect of the micro-electro discharge machining (EDM) milling machinability of Si3N4–TiN workpieces was investigated. The material removal rate (MRR) and tool wear rate (TWR) were analyzed in relation to discharge pulse types in order to evaluate how the different pulse shapes impact on such micro-EDM performance indicators. Voltage and current pulse waveforms were acquired during micro-EDM trials, scheduled according to a Design of Experiment (DOE); then, a pulse discrimination algorithm was used to post-process the data off-line and discriminate the pulse types as short, arc, delayed, or normal. The analysis showed that, for the considered process parameter combinations, MRR was sensitive only to normal pulses, while the other pulse types had no remarkable effect on it. On the contrary, TWR was affected by normal pulses, but the occurrence of arcs and delayed pulses induced unexpected improvements in tool wear. Those results suggest that micro-EDM manufacturing of Si3N4–TiN workpiece is relevantly different from the micro-EDM process performed on metal workpieces such as steel. Additionally, the inspection of the Si3N4–TiN micro-EDM surface, performed by SEM and EDS analyses, showed the presence of re-solidified droplets and micro-cracks, which modified the chemical composition and the consequent surface quality of the machined micro-features.
Highlights
Silicon nitride-based ceramics constitute a class of structural materials characterized by high strength, fracture toughness, thermal shock resistance, wear resistance, low coefficient of friction, and hardness
The analysis showed that, for the considered process parameter combinations, material removal rate (MRR) was sensitive only to normal pulses, while the other pulse types had no remarkable effect on it
A pulse-type discrimination strategy was implemented and applied to micro-electro discharge machining (EDM) milling of hardened steel in order to investigate the influence of process parameters on discharge shapes and process performance [15]; the study emphasized the importance of sparking gap and feed rate for the process stability and identified that tool wear increase could be associated to the increase of arc number
Summary
Silicon nitride-based ceramics constitute a class of structural materials characterized by high strength, fracture toughness, thermal shock resistance, wear resistance, low coefficient of friction, and hardness. A pulse-type discrimination strategy was implemented and applied to micro-EDM milling of hardened steel in order to investigate the influence of process parameters on discharge shapes and process performance [15]; the study emphasized the importance of sparking gap and feed rate for the process stability and identified that tool wear increase could be associated to the increase of arc number. Local machining conditions, such as the presence of unremoved debris in the sparking gap, can promote discharge events independently of the pulse generator; in this case, two types of pulses can be observed: arcs and delayed The distinction between these two categories can be made based on the maximum voltage value.
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