Machining Of Ceramics Research Articles

Role of ceramics in machining of composite materials: A comprehensive review

Role of ceramics in machining of composite materials: A comprehensive review

A comparative study on machinability of ceramics with different mechanical properties in diamond wire sawing

Ceramics thin substrates are widely used in electronic devices due to their excellent physical and mechanical properties. Diamond wire sawing is one of promising manufacturing route to prepare thin ceramic substrates from sintered ceramics block. In present paper, a comparative study on diamond wire sawing of Al2O3, AlN, ZrO2 and Si3N4 ceramics was carried out. The material removal rate (MRR), wire sawing force and surface integrity of different ceramics as well as the wear characteristics of diamond wire were examined. A finite element model (FEM) for the single-grain cutting of different ceramic materials was developed to elucidate the influence of the mechanical properties of these ceramics on both surface morphology and the cutting force. The results show that mechanical properties of ceramic materials have great influence on diamond wire sawing performance. The Al2O3 and AlN with lower fracture toughness exhibit better machinability than that of ZrO2 and Si3N4. AlN has the highest MRR (0.128 mm3/min) and the smallest tangential sawing force (0.0255 N), while Si3N4 presents the lowest MRR (0.101 mm3/min) and ZrO2 owns the largest wire sawing force (0.238 N) under wire speed of 1.3 m/s. For the sawn surface of ceramics, Si3N4 shows the lowest surface roughness (Ra 0.23 μm), followed by ZrO2 (Ra 0.44 μm) and AlN (Ra 0.57 μm), while Al2O3 exhibits the highest surface roughness (Ra 0.62 μm). In sawing of ZrO2 and Si3N4, the electroplated diamond grits tend to flatten or fall-off, producing severer wear of diamond wire than that of Al2O3 and AlN, and deteriorating the sawing capability of the diamond wire.

Research on the thermal energy environment and process parameters of milling process in ceramic art design

In ceramic art design, milling technology is the key processing technology, which directly affects the quality and artistic expression of ceramic products. However, the thermal energy environment generated in the milling process has a significant impact on the material characteristics and machining results. This study aims to explore the influence of the thermal energy environment on the ceramic art design during the milling process, optimize the process parameters, and improve the processing efficiency and product quality. Experiments with different milling speed, feed rate and cutting depth were designed to compare and analyze the change of thermal environment by combining experiment and simulation. The influence of thermal energy on ceramic machining quality was evaluated by monitoring the temperature distribution in the cutting process with thermal imaging technology and combining with the experimental data of material properties. The experimental results show that the temperature increase in milling process is closely related to the cutting speed and feed rate, and proper control of the thermal energy environment can significantly reduce the crack generation rate and improve the surface finish of ceramic materials. The optimized process parameters make the temperature control in the milling process within the ideal range, thus realizing the processing of high quality ceramic products. Through reasonable optimization of process parameters, the heat energy in the processing process can be effectively controlled, which helps to improve the overall quality and artistic value of ceramic works.

Effect of oxygen doping on cutting performance of CVD diamond coated milling cutters in zirconia ceramics machining

Diamond thin films were deposited on WC-Co tools using the hot-filament chemical vapor deposition (HFCVD) technique at varying pressures and oxygen doping levels. As the oxygen doping content increased, the purity of the diamond phase improved, and the density of the <111> crystal plane on the film's surface increased. The growth rate of diamond films initially increased and then decreased under low pressure, with a corresponding decrease in residual compressive stress. Conversely, at high pressure, increased oxygen doping enhanced the diamond phase purity and growth rate while reducing residual compressive stress. Cutting experiments on pre-sintered zirconia ceramics for milling linear slots and engraving dentures demonstrated that diamond-coated milling cutters exhibited superior cutting performance under consistent oxygen and carbon source concentrations and stable air pressure conditions. The oxygen-doped diamond-coated milling cutter grown at a pressure of 1 KPa exhibited the longest service life, attributed to its reduced surface roughness, lower cutting force, and increased density of the <111> crystal plane orientation. This cutter could machine up to 1300 crowns, making it approximately 80% more durable than non‑oxygen-doped diamond-coated milling cutters and about 20 times more durable than uncoated ones.

ТЕХНОЛОГИЧЕСКИЕ МЕТОДЫ ФОРМООБРАЗОВАНИЯ КАЧЕСТВЕННОЙ ПОВЕРХНОСТИ ДЕТАЛЕЙ ИЗ АЛЮМИНИЕВЫХ И МЕДНЫХ СПЛАВОВ

The surface quality of aluminum and copper alloy parts is studied when they are formed, which is important for transport engineering. The main task is to determine the conditions conducive to the formation of specified criteria for surface quality and to find out the dependencies of various factors when applying edge cutting machining and electrochemical processes. The research includes experimental and analytical parts, which are presented as conclusions, including the most optimal modes and conditions in terms of quality formation. The research methods are of an experimental and practical nature with the comparison and evaluation of the results obtained, in which the features of porous metal ceramics machining and methods for improving the efficiency of surface forming while maintaining the functional physical parameters of the part surfaces are considered. The novelty of the study is in finding dependencies of the obtained quality on the machining conditions and the comparative characteristics of the obtained surfaces not only in terms of changes in roughness, but also in surface porosity. As a result, recommendations are made for machining such materials, which minimize the effect of pore tightening and reduce deformation phenomena in the material.

Research on the Influence of Alumina Ceramic Microstructure on Diamond Wire Sawing

Ceramic materials are widely used in national defense, military industry, information technology and other fields, are a typical hard and brittle material. Microstructure and mechanical properties not only affect the overall performance of ceramic parts, but also affect their machining performance. The diamond wire sawing technology has the characteristics of high machining efficiency, small crack damage, low cutting loss, and green environmental protection, and is widely used in the cutting of hard and brittle materials. Therefore, exploring the influence of ceramic microstructure on diamond wire sawing has theoretical significance and practical value. This article first prepares high-performance alumina ceramics with different grain sizes to provide preliminary material preparation for diamond wire sawing; Then, characterization experiments such as microstructure, mechanical properties, fracture and indentation morphology, and indentation depth were conducted to provide technical methods for in-depth research on material removal in diamond wire sawing; Finally, the removal form, chips, roughness, and removal rate of diamond wire sawing were studied to obtain the influence of different microstructures of alumina ceramics on diamond wire sawing, providing a certain theoretical and technical basis for efficient machining of high-performance ceramics by diamond wire saw.

The effect of h-BN content on mechanical properties, microstructure and machinability of hot-pressed h-BN/Si3N4 composites

Si3N4 ceramics now face new applications and challenges in the semiconductor field. The preparation of h-BN/Si3N4 machinable ceramics incorporating 5–30 vol% h-BN via hot-pressing was carried out. This study systematically explored how the varying h-BN content influenced the composite's microstructure, mechanical attributes, and machinability. The results showed that some of the h-BN was encapsulated by growing Si3N4 grains to form an intragranular structure during the process of hot-pressing, while the remaining h-BN exhibited uniform distribution along grain boundaries. The Si3N4 phase transition in composites was inhibited by excessive h-BN, accompanied by a higher decrease in densification. The sample containing 20 vol% h-BN exhibited the best comprehensive performance, with high mechanical strength and excellent machinability. The bending strength and fracture toughness remained high at 862 MPa and 10.3 MPa m1/2, and could be effortlessly machined with cemented carbide drills. Additionally, the machinability of the composites was systematically characterized through observations of crack propagation paths, fitting of R-curves, and mechanical drilling tests.

Ultrafast processing of zirconia ceramics by transient and selective laser absorption

Ultrashort-pulse lasers (USPLs) are used in the machining of zirconia ceramics (ZrO2) because of their extremely high peak intensities. However, highly efficient and high precision microprocessing of ZrO2 remains challenging. In this study, we applied a transient and selective laser (TSL) processing technique by combining a USPL and a continuous-wave (CW) laser to realize ultrafast drilling of opaque ZrO2. Ultra-high-efficiency TSL drilling of ZrO2 was achieved with a processing efficiency 1800 times higher than that of USPL drilling. The material removal mechanism, hole formation process, and parameter dependence of TSL drilling were revealed by direct observation of the internal processing phenomenon on a timescale of microseconds. The variations in the processed surface characteristics, including surface morphology, elemental composition, and phase composition, are also presented. Subsequently, the effect of different excited electron regions occurring in the picosecond timescale induced by the USPL on the TSL drilling performance is discussed. Finally, the repeatability and stability of the TSL processing were verified by fabricating microarrays of different sizes. This study will contribute to revealing the ultrafast processing mechanisms of TSL processing in ZrO2 microfabrication. Furthermore, this technique can significantly broaden the applications of ZrO2 in the advanced electronic industry by greatly improving the microprocessing efficiency.

Development of conductive SiC-ZrN-TiB2 ceramics: A pathway towards electrical discharge machinable SiC based ceramics

Dense silicon carbide (SiC) composites with 0–30 vol% (ZrN-TiB2) were fabricated by using liquid phase spark plasma sintering at a relatively lower sintering temperature (1800 °C) and shorter holding time (5 min). The effects of co-addition of ZrN and TiB2 on densification, mechanical properties, and electrical conductivity of SiC ceramics were investigated. The reinforcement significantly enhanced density of sintered composites, while the phase analysis and microstructure confirm the suppression of β→α phase transformation in the SiC matrix. The fracture toughness ranged from 4.1 to 4.6 MPa·m0.5, hardness from 19.5 to 20.3 GPa, and electrical conductivity from 4.85 ×101 to 1.25 ×103 (Ω·cm)−1. Incorporating conductive reinforcements and nitrogen additives enhanced electrical conductivity. Successful wire-EDM cutting of SiC-ZrN-TiB2 composites demonstrate the feasible alternative to conventional machining of non-oxide ceramics with a maximum material removal rate of 8.54 mm2/min.

Advancements in multi-material additive manufacturing of advanced ceramics: A review of strategies, techniques and equipment

Ceramics possess notable attributes including excellent wear resistance, exceptional high-temperature strength, superior hardness, and outstanding biocompatibility, rendering them indispensable for the fabrication of key industrial components. Additive manufacturing presents significant benefits such as precise fabrication, design flexibility, and the ability for mass customization. This technology facilitates the creation of intricate structural or functional ceramic components with complex geometries, effectively addressing issues that are inadequately managed by conventional methods, such as the inherent brittleness of ceramics and challenges associated with ceramic machining. As advancements in aerospace, special industry, and biomedical sectors progress, the performance limitations of uniform ceramic materials and structures have emerged as a bottleneck constraining the broadening of their application range. There is a pressing need to transition from single-material ceramic additive manufacturing to multi-material printing. This paper highlights and compares various notable advancements in typical single-material ceramic additive manufacturing. In addition, it delves into the present status of multi-material ceramic additive continuous forming and the development of associated equipment, focusing on different forming mechanisms. Finally, the paper concludes by identifying the primary challenges and research priorities in multi-material ceramic additive manufacturing, and suggests potential directions for future development.

Optimization of surface roughness and tool wear in laser-assisted machining of alumina ceramics using Taguchi method

Optimization of surface roughness and tool wear in laser-assisted machining of alumina ceramics using Taguchi method

Surface topography characterization of USMM during machining of zirconia ceramic using silicon carbide abrasives: An experimental and simulation approach

Zirconia is a highly biodegradable ceramic material with excellent fracture resistance, in biomedical engineering, particularly dental implants. This research work has been focused on optimizing the quality of micro-hole generation in zirconia ceramic through ultrasonic micromachining (USMM). Three key process parameters such as abrasive slurry concentration, tool feed rate, and power rating are considered in this research work. The material removal rate, overcut, and taper angle are considered as responses. Response surface methodology has been employed for modeling during the USMM process, and a mathematical model has been developed to understand material removal mechanisms. Finite element analysis has been utilized to provide insights into the impacting process for industry requirements. A 3D model has been created to perform dynamic analysis under practical conditions. Multi-objective optimization has been applied to achieve optimum material removal rate (MRR), overcut, and taper angle. From multi-objective optimization, a slurry concentration of 49.59% g/l, tool feed rate of 1.16 mm/min, and power rating of 386.87 W has been found and in this parameter settings maximum MRR of 0.5333 mm3/min, minimum taper angle of 0.3428 degrees, and minimum overcut of 36.64 µm has been obtained during machining of ZrO2 ceramics.

Temperature field simulation and optimization of processing parameters for laser-assisted machining of 3Y-TZP ceramics

To obtain low surface roughness in the laser-assisted machining of 3Y-TZP ceramics, a laser-assisted heating model of 3Y-TZP ceramics was established. The temperature field in the cutting zone was simulated using ABAQUS software to analyze the effects of laser power, rotational speed, and warm-up time on softening layer depth (distance between the workpiece surface and lower boundary of softening layer) and thickness (distance between the upper and lower boundaries of softening layer). Furthermore, the accuracy of the simulation results was verified through experiments. The Plackett-Burman design, Steepest ascent experiment, and Box-Behnken design method were used sequentially to optimize process parameters, and the surface quality, chip morphology, and tool wear of 3Y-TZP ceramic with laser-assisted cutting and traditional cutting were compared under the best process parameters. The results show that the rotational speed and laser power are the main factors influencing the softening layer depth and thickness, and the suitable warm-up time is 15 s; the most influential factor on the surface roughness is the cutting depth, and the optimized process parameter combinations for the best surface roughness are as follows: laser power of 90.3 W, rotational speed of 400 r/min, cutting depth of 0.21 mm, and feed speed of 4.4 mm/min; with laser-assisted, the surface roughness value of the workpiece is reduced by 54.12 %, the amount of tool wear is reduced by 56.5 %, the chip morphology is transformed from powder to strip with a length of more than 50 μm, and the primary material removal mode is changed from brittle removal to plastic removal.

Eco-friendly machining of advanced ceramics: wheel cleaning jet for greenhouse gas reduction

Eco-friendly machining of advanced ceramics: wheel cleaning jet for greenhouse gas reduction

Structural and Mechanical Properties of SiC-Rich By-Products of the Metal Grade Si Process

Mechanical properties of composites produced from the SiC-rich furnace slag using traditional stone and ceramic machining technologies were studied. A non-uniform mixture of coarse monocrystalline SiC grains soaked with Si-metal and glassy oxide phases represented the microstructure of dense monolithic SiC-rich samples. The fracture mechanism of coarse-grained SiC-rich composites was susceptible to the grain size/sample geometry and machining conditions yielding flexural strength in the range of 50-106 MPa and high compression strength of 750 MPa. Despite inhomogeneous macro and microstructure, mechanical and thermal properties are comparable to the traditionally produced siliconized SiSiC ceramics. It opens up the opportunity for the circular economy and value-added recycling of the Si/FeSi industries’ wastes.

Investigation on Enhanced Machinability of SiC Ceramics through Photocatalytic Vibration Composite Polishing.

The problems of low polishing efficiency and serious surface damage in the processing of silicon carbide (SiC) ceramics are well-known. In view of the above problems, a new method of photocatalytic vibration composite polishing (PVCP) combined with a compound control strategy was proposed. A vibration-assisted device was developed, and a compound control system was designed for the device to improve the trajectory tracking accuracy. Experiments were carried out to verify the effectiveness of the vibration-assisted device and the compound control system. In addition, methyl orange degradation and fading experiments, redox potential measurement experiments, and SiC ceramic surface hardness characterization experiments were carried out to reveal the effects of vibration and photocatalytic parameters on polishing solution oxidation and SiC ceramic surface mechanical properties. Finally, the effects of photocatalysis, vibration frequency, amplitude, and the compound control system on the polishing effect were analyzed. The results show that when the UV intensity is 100%, the polishing force is 3-4N, the vibration frequency is 400 Hz, the amplitude is 15 μm, and the surface roughness of SiC ceramics is reduced by about 11 nm after the introduction of the compound control system, which verifies the effectiveness of the combination of the compound control system and PVCP.

Machining characteristics in ultrasonic vibration-assisted powder-mixed electrical discharge machining of TiN ceramics

This study aims to investigate the application and machining characteristics of brittle conductive ceramics using ultrasonic vibration-assisted powder-mixed electrical discharge machining (UV-PMEDM) technology. Titanium nitride (TiN) ceramics are widely used in aerospace, biomedicine, and electronics due to their excellent properties. However, the conventional mechanical machining methods of these materials result in severe tool wear, high costs, and low efficiency. Although electrical discharge machining (EDM) can overcome some limitations, it typically exhibits a low material removal rate and poor surface quality. This study utilizes the UV-PMEDM technology to process TiN ceramics. Single-factor experiments are conducted to analyze the effects of processing parameters, including ultrasonic amplitude, powder concentration, pulse-on time, and pulse-off time, on the material removal rate, surface roughness, and relative electrode wear rate, which indicate the EDM processing performance. With the assistance of ultrasonic vibration and mixed powders, the material removal rate of TiN ceramics using UV-PMEDM reaches 0.50 mm3/min, while maintaining a relative electrode wear rate below 1 % and surface roughness lower than 4.2 μm. The synergistic combination of ultrasonic vibration and mixed powders significantly enhances the processing efficiency and reduces surface roughness of TiN ceramics. These findings contribute to a better understanding of machining strategies for brittle conductive ceramics.

Study on the surface formation mechanism and theoretical model of brittle surface roughness in turning machinable ceramics

Study on the surface formation mechanism and theoretical model of brittle surface roughness in turning machinable ceramics

Experimental Study on ELID Grinding of Silicon Nitride Ceramics for G5 Class Bearing Balls

This study has focused on analyzing the impact of material characteristics and grinding conditions on the surface roughness in ELID grinding of ceramic materials intended for bearing balls. The main research objective was to examine the feasibility of achieving the required surface roughness for G5 class bearing balls through a high-efficiency and high-precision ELID grinding process. Three types of silicon nitride specimens and two types of grinding wheels with cBN and diamond abrasives were prepared for the experiments. An HP (high-pressure) specimen was fabricated through high-temperature and high-pressure sintering at 1700 °C for 2 h, containing a composition of Y2O3 and MgO in Si3N4, while GPS 1hr and GPS 6hr specimens were prepared using gas-pressure sintering for 1 h and 6 h, respectively. From the experimental results, it has been confirmed through surface morphology and surface roughness analysis that material characteristics and grinding parameters affect the surface roughness of silicon nitride ceramics during the grinding process. The surface ground with a #2000 diamond wheel is at a level that can satisfy the required surface roughness, 0.014 um or less in G5 class bearing balls. Based on the analysis of surface morphology and roughness in grinding processes, the #325 cBN wheel exhibited excellent performance in rough grinding, while the #2000 diamond wheel demonstrated highly effective surface finishing performance, indicating that the combination of these two abrasives can be effectively utilized for high-efficiency and high-precision nanosurface machining of silicon nitride ceramics.

Experimental study of plastic cutting in laser-assisted machining of SiC ceramics

In this paper, the cutting process of laser-assisted machining (LAM) of SiC ceramics is studied. Three processing states of brittleness, plasticity and thermal damage are determined based on the characterization analysis of surface integrity, tool wear and chip morphology, and the surface roughness and tool wear regression model established under the plastic processing state are verified. Firstly, the surface integrity, tool wear and chip morphology are investigated by the single-factor experiment of laser power to explain the material removal mechanism according to the material fracture theory and to determine the laser power range of plastic cutting (185 W–225 W). Then the Box-Benhnken experimental scheme is designed to establish a multivariate prediction model based on the response surface methodology (RSM) to obtain the regression equation of surface roughness and tool wear and further analyze the interaction between process parameters. Finally, the experimental values of surface roughness and tool wear are compared with the predicted values through optimization analysis. The results show that the maximum error is 5 % and 7.57 % respectively, which proves that the model has good prediction ability. The surface roughness and tool wear regression prediction models provide guidance for the selection of plastic cutting process parameters for SiC ceramics.