Micro electro discharge machining of nonconductive ceramic: the issue of spalling

Nonconductive ceramic materials are used in many engineering applications such as car brake, turbine blade, and hip-bone replacement because of its high dimensional accuracy, corrosion and wear resistant, and biocompatibility. These materials are usually processed with diamond grinding and limited l...

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Main Authors:	Ali, Mohammad Yeakub, Sabur, Abdus, Maleque, Md. Abdul
Format:	Article
Language:	English English
Published:	Science Publishing Corporation Inc 2018
Subjects:	T Technology (General) T175 Industrial research. Research and development TJ Mechanical engineering and machinery TS Manufactures
Online Access:	http://irep.iium.edu.my/66449/ http://irep.iium.edu.my/66449/ http://irep.iium.edu.my/66449/ http://irep.iium.edu.my/66449/1/IJET-17297.pdf http://irep.iium.edu.my/66449/7/66449_Micro%20Electro%20Discharge%20Machining%20of%20Nonconductive_scopus.pdf

id	iium-66449
recordtype	eprints
spelling	iium-664492018-10-08T04:50:16Z http://irep.iium.edu.my/66449/ Micro electro discharge machining of nonconductive ceramic: the issue of spalling Ali, Mohammad Yeakub Sabur, Abdus Maleque, Md. Abdul T Technology (General) T175 Industrial research. Research and development TJ Mechanical engineering and machinery TS Manufactures Nonconductive ceramic materials are used in many engineering applications such as car brake, turbine blade, and hip-bone replacement because of its high dimensional accuracy, corrosion and wear resistant, and biocompatibility. These materials are usually processed with diamond grinding and limited laser applications such as cutting, drilling and scribing. Specific shapes and profiles are still difficult and costly to machine using these processes. Electrical discharge machining (EDM), extensively used for various shapes and profiles on con-ductive materials having minimum electrical conductivity of 0.10 S.cm-1. It is not directly applicable on nonconductive ceramic materi-als due to its very low electrical conductivity (<10-10 S.cm-1). However, recently EDM is used on nonconductive materials with the aid of assisting electrode to initiate the spark between conductive tool electrode and nonconductive workpiece. The available material re-moval models of EDM are based on single spark erosion with uniform melting and vaporization of workpiece materials. However, in EDM of nonconductive ceramics, material removal is not uniform because of random spalling due to alternating thermal stress. In addi-tion, it is difficult to create single spark erosion on a nonconductive ceramic workpiece as initial sparks are occurred between tool elec-trode and assisting electrode attached to workpiece. This paper presents the empirical factor for the estimation of spalling along with melting and vaporization through experimental study. Model of material removal rate as a function of capacitance and voltage are devel-oped in micromachining of nonconductive zirconium oxide (ZrO2) using (R-C) pulse type micro-EDM. The single spark erosion volume is derived from the fundamental principle of melting and vaporization. An empirical correction factor is introduced to compensate ran-dom spalling and multi-spark erosion effect. Science Publishing Corporation Inc 2018 Article PeerReviewed application/pdf en http://irep.iium.edu.my/66449/1/IJET-17297.pdf application/pdf en http://irep.iium.edu.my/66449/7/66449_Micro%20Electro%20Discharge%20Machining%20of%20Nonconductive_scopus.pdf Ali, Mohammad Yeakub and Sabur, Abdus and Maleque, Md. Abdul (2018) Micro electro discharge machining of nonconductive ceramic: the issue of spalling. International Journal of Engineering and Technology, 7 (3). pp. 32-39. E-ISSN 2227-524X https://www.sciencepubco.com/index.php/ijet/article/view/17297 10.14419/ijet.v7i3.24.17297
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English English
topic	T Technology (General) T175 Industrial research. Research and development TJ Mechanical engineering and machinery TS Manufactures
spellingShingle	T Technology (General) T175 Industrial research. Research and development TJ Mechanical engineering and machinery TS Manufactures Ali, Mohammad Yeakub Sabur, Abdus Maleque, Md. Abdul Micro electro discharge machining of nonconductive ceramic: the issue of spalling
description	Nonconductive ceramic materials are used in many engineering applications such as car brake, turbine blade, and hip-bone replacement because of its high dimensional accuracy, corrosion and wear resistant, and biocompatibility. These materials are usually processed with diamond grinding and limited laser applications such as cutting, drilling and scribing. Specific shapes and profiles are still difficult and costly to machine using these processes. Electrical discharge machining (EDM), extensively used for various shapes and profiles on con-ductive materials having minimum electrical conductivity of 0.10 S.cm-1. It is not directly applicable on nonconductive ceramic materi-als due to its very low electrical conductivity (<10-10 S.cm-1). However, recently EDM is used on nonconductive materials with the aid of assisting electrode to initiate the spark between conductive tool electrode and nonconductive workpiece. The available material re-moval models of EDM are based on single spark erosion with uniform melting and vaporization of workpiece materials. However, in EDM of nonconductive ceramics, material removal is not uniform because of random spalling due to alternating thermal stress. In addi-tion, it is difficult to create single spark erosion on a nonconductive ceramic workpiece as initial sparks are occurred between tool elec-trode and assisting electrode attached to workpiece. This paper presents the empirical factor for the estimation of spalling along with melting and vaporization through experimental study. Model of material removal rate as a function of capacitance and voltage are devel-oped in micromachining of nonconductive zirconium oxide (ZrO2) using (R-C) pulse type micro-EDM. The single spark erosion volume is derived from the fundamental principle of melting and vaporization. An empirical correction factor is introduced to compensate ran-dom spalling and multi-spark erosion effect.
format	Article
author	Ali, Mohammad Yeakub Sabur, Abdus Maleque, Md. Abdul
author_facet	Ali, Mohammad Yeakub Sabur, Abdus Maleque, Md. Abdul
author_sort	Ali, Mohammad Yeakub
title	Micro electro discharge machining of nonconductive ceramic: the issue of spalling
title_short	Micro electro discharge machining of nonconductive ceramic: the issue of spalling
title_full	Micro electro discharge machining of nonconductive ceramic: the issue of spalling
title_fullStr	Micro electro discharge machining of nonconductive ceramic: the issue of spalling
title_full_unstemmed	Micro electro discharge machining of nonconductive ceramic: the issue of spalling
title_sort	micro electro discharge machining of nonconductive ceramic: the issue of spalling
publisher	Science Publishing Corporation Inc
publishDate	2018
url	http://irep.iium.edu.my/66449/ http://irep.iium.edu.my/66449/ http://irep.iium.edu.my/66449/ http://irep.iium.edu.my/66449/1/IJET-17297.pdf http://irep.iium.edu.my/66449/7/66449_Micro%20Electro%20Discharge%20Machining%20of%20Nonconductive_scopus.pdf
first_indexed	2023-09-18T21:34:21Z
last_indexed	2023-09-18T21:34:21Z
_version_	1777412720525574144

Micro electro discharge machining of nonconductive ceramic: the issue of spalling

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