Abstract
Non-conductive structural ceramics are receiving ever-increasing attention due to their outstanding physical and mechanical properties and their critical applications in aerospace and biomedical industries. However, conventional mechanical machining seems infeasible for the machining of these superior ceramics due to their extreme brittleness and higher hardness. Electro discharge machining (EDM), well known for its machining of electrically conductive materials irrespective of materials hardness, has emerged as a potential machining technique due to its noncontact nature when complemented with an assistive electrode technique. This paper investigates the material removal mechanism and effects of machining parameters on machining speed and dimensional and profile accuracies of features machined on zirconia toughened alumina (ZTA) ceramics using assistive electrode EDM. Our experimental results demonstrate that both increasing peak current and pulse on time improves the MRR, however, it also aids in generating thicker layer on machined surface. In addition, pulse interval time is crucial for the machining of nonconductive ceramics, as larger value might cause the complete removal of intrinsic carbon layer which may lead to non/sparking condition. Higher peak current increases circularity whereas short pulse on and pulse off time aid in increasing circularity due to rough machining. In addition, taperness is found to be regulated by the peak current and pulse on time. Overall, thermal cracking and spalling appear to be a dominating material removal mechanism other than melting and evaporation for the EDM of ZTA.
Highlights
Ceramics are considered as one of the outstanding structural materials due their excellent properties such as high hardness, higher strength, superior chemical stability, low density, high temperature strength, high wear resistance, and biocompatibility
This study investigates the material removal mechanism and effects of machining parameters on the material removal rate and dimensional and profile accuracies of ma‐
This study investigates the material removal mechanism and effects of machining parameters on the material removal rate and dimensional and profile accuracies of machined blind holes during Electro discharge machining (EDM) of Zirconia-toughened Alumina (ZTA)
Summary
Ceramics are considered as one of the outstanding structural materials due their excellent properties such as high hardness, higher strength, superior chemical stability, low density, high temperature strength, high wear resistance, and biocompatibility. Because of these superior characteristics, ceramic materials found their application as cutting tools and in the aerospace and biomedical industries [1]. The conventional machining of ceramics faces challenges such as high cutting forces, higher tool consumption, the generation of microcracks in mechanical machining, and complex and expensive manufacturing cycle specially in the final stage of machining. Micromachines 2021, 12, 67 machining, electrochemical machining, abrasive water jet machining that contributes towards the machining of ceramics.
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
