Advertisement

Investigation on machining performance of micro-holes EDM in ZrB2-SiC ceramics using a magnetic suspension spindle system

  • Yerui Feng
  • Yongfeng GuoEmail author
  • Zebin Ling
  • Xiaoyou Zhang
ORIGINAL ARTICLE
  • 32 Downloads

Abstract

Zirconium diboride-silicon carbide (ZrB2-SiC) ceramics are considered to be potential candidates for ultra-high temperature (> 2200 °C) applications due to unique combination of properties. However, it is difficult to machine micro-hole in ZrB2-SiC with a high precision by traditional methods owing to its highly mechanical strength. Here, an effective method to machining micro-holes on ZrB2-SiC ceramics was presented, by using a magnetic suspension spindle system (MSSS) electrical discharge machining (EDM) which possesses high response frequency. The objective of this experimental work is to study effects of machining parameters of MSSS EDM on discharge percentage, material removal rate (MRR), electrode wear rate (EWR), and lateral surface quality. Experimental results reveal that compared to micro-holes machined by conventional EDM, with the application of MSSS EDM, discharge percentage increased by at least 28%, and arc percentage decreased by at least 16.3%. Hence, MRR increased by at least 35% and EWR decreased by at least 51%. The inlet and outlet diameters of the micro-holes and the lateral surface of the holes significantly improved with using MSSS EDM. The experimental results demonstrate that compared to conventional EDM, MSSS EDM can be used to fabricate micro-holes on ZrB2-SiC ceramics with a higher efficiency and quality.

Keywords

Micro-EDM Magnetic suspension spindle system ZrB2-SiC ceramics Surface quality 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

This project is supported by the National Natural Science Foundation of China (Grant No. 51875132), and Heilongjiang Province Nature Science Foundation (E2016037).

References

  1. 1.
    Jin XX, He RJ, Zhang XH, Hu P (2013) Ablation behavior of ZrB2–SiC sharp leading edges. J Alloys Compd 566:125–130CrossRefGoogle Scholar
  2. 2.
    Zapata-Solvas E, Jayaseelan DD, Lin HT, Brown P, Lee WE (2013) Mechanical properties of ZrB2- and HfB2-based ultra-high temperature ceramics fabricated by spark plasma sintering. J Eur Ceram Soc 33(7):1373–1386CrossRefGoogle Scholar
  3. 3.
    Sivasankar S, Jeyapaul R (2016) Characterization of ZrB2-SiC composites with an analytical study on material removal rate and tool wear rate during electrical discharge machining. Trans-Can Soc Mech Eng 40(3):331–349CrossRefGoogle Scholar
  4. 4.
    Saccone G, Gardi R, Alfano D, Ferrigno A, Vecchio AD (2016) Laboratory, on-ground and in-flight investigation of ultra high temperature ceramic composite materials. Aerosp Sci Technol 58:490–497CrossRefGoogle Scholar
  5. 5.
    Monteverde F, Bellosi A, Scatteia L (2008) Processing and properties of ultra-high temperature ceramics for space applications. Mater Sci Eng A 485(1):415–421CrossRefGoogle Scholar
  6. 6.
    Du BH, Li N, Ke B, Xing PF, Jin XX, Hu P, Zhang XH (2016) ZrB2-SiC composites’ surface temperature response to dissociated oxygen at 1600 °C. Ceram Int 42:14292–14297CrossRefGoogle Scholar
  7. 7.
    Zhou P, Hu P, Zhang XH, Han WB (2011) Laminated ZrB2–SiC ceramic with improved strength and toughness. Scr Mater 64:276–279CrossRefGoogle Scholar
  8. 8.
    Lauwers B, Kruth JP, Liu W, Eeraerts W, Schacht B, Bleys P (2004) Investigation of material removal mechanisms in EDM of composite ceramic materials. J Mater Process Technol 149(1–3):347–352CrossRefGoogle Scholar
  9. 9.
    Wang L, Guo YF, Zhang GW (2017) Investigation on conductive layer, delamination, and recast layer characteristics of electro-discharge machined holes in TBCs. J Mater Eng Perform 26(5):2394–2403CrossRefGoogle Scholar
  10. 10.
    Qian J, Yang F, Wang J, Lauwers B, Reynaerts D (2015) Material removal mechanism in low-energy micro-EDM process. CIRP Ann Manuf Technol 64(1):225–228CrossRefGoogle Scholar
  11. 11.
    Alavi F, Jahan MP (2017) Optimization of process parameters in micro-EDM of Ti-6Al-4V based on full factorial design. Int J Adv Manuf Technol 92(1–4):167–187CrossRefGoogle Scholar
  12. 12.
    Singh P, Yadava V, Narayan A (2018) Machining performance characteristics of Inconel 718 superalloy due to hole-sinking ultrasonic assisted micro-EDM. J Adv Manuf Syst 17(1):89–105CrossRefGoogle Scholar
  13. 13.
    Ji RJ, Liu YH, Zhang YZ, Cai BP, Ma JM, Li XP (2012) Influence of dielectric and machining parameters on the process performance for electric discharge milling of SiC ceramic. Int J Adv Manuf Technol 59(1–4):127–136CrossRefGoogle Scholar
  14. 14.
    Ji RJ, Liu YH, Zhang YZ, Wang F (2011) Machining performance of silicon carbide ceramic in end electric discharge milling. Int J Refract Met Hard Mater 29(1):117–122CrossRefGoogle Scholar
  15. 15.
    Ji RJ, Liu YH, Zhang YZ, Cai BP, Li H, Ma JM (2010) Optimizing machining parameters of silicon carbide ceramics with ED milling and mechanical grinding combined process. Int J Adv Manuf Technol 51(1–4):195–204CrossRefGoogle Scholar
  16. 16.
    Sivasankar S, Jeyapaul R (2016) Modelling of an artificial neural network for electrical discharge machining of hot pressed zirconium diboride-silicon carbide composites. Trans Famena 40(3):67–80CrossRefGoogle Scholar
  17. 17.
    Krupa MS, Kumar ND, Kumar RS, Chakravarthy P, Venkateswarlu K (2013) Effect of zirconium diboride addition on the properties of silicon carbide composites. Ceram Int 39(8):9567–9574CrossRefGoogle Scholar
  18. 18.
    Nakamura M, Shigematsu I, Kanayama K, Hirai Y (1991) Surface damage in ZrB2-based composite ceramics induced by electro-discharge machining. J Mater Sci 26(22):6078–6082CrossRefGoogle Scholar
  19. 19.
    Patel M, Prasad VVB (2016) Effect of method of sample preparation on strength of zirconium diboride (ZrB2). Trans Indian Inst Metals 70(4):1–7Google Scholar
  20. 20.
    Zhang M, Guo D, Jin Z (2009) EDM performance of electroformed Cu-ZrB2 shell electrodes. Rapid Prototyp J 15(2):150–156CrossRefGoogle Scholar
  21. 21.
    Zaw HM, Fuh JYH, Nee AYC, Lu L (1999) Formation of a new EDM electrode material using sintering techniques. J Mater Process Technol 89–90(99):182–186CrossRefGoogle Scholar
  22. 22.
    Norasetthekul S, Eubank PT, Bradley WL, Bozkurt B, Stucker B (1999) Use of zirconium diboride-copper as an electrode in plasma applications. J Mater Sci 34(6):1261–1270CrossRefGoogle Scholar
  23. 23.
    Czelusniak T, Amorim FL, Lohrengel A, Higa CF (2014) Development and application of copper–nickel zirconium diboride as EDM electrodes manufactured by selective laser sintering [J]. Int J Adv Manuf Technol 72(5–8):905–917CrossRefGoogle Scholar
  24. 24.
    Wang J, Han FZ, Cheng G, Zhao FL (2012) Debris and bubble movements during electrical discharge machining. Int J Mach Tool Manu 58:11–18CrossRefGoogle Scholar
  25. 25.
    Ayesta I, Flano O, Izquierdo B, Sanchez JA, Plaza S (2016) Experimental study on debris evacuation during slot EDMing. Procedia CIRP 42:6–11CrossRefGoogle Scholar
  26. 26.
    Guo YF, Ling ZB, Zhang XY (2016) A novel PWM power amplifier of magnetic suspension spindle control system for micro EDM. Int J Adv Manuf Technol 83(5–8):961–973CrossRefGoogle Scholar
  27. 27.
    Guo YF, Ling ZB, Zhang XY, Feng YR (2018) A magnetic suspension spindle system for small and micro holes EDM. Int J Adv Manuf Technol 94(5–8):1911–1923CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Yerui Feng
    • 1
  • Yongfeng Guo
    • 1
    Email author
  • Zebin Ling
    • 1
  • Xiaoyou Zhang
    • 2
  1. 1.School of Mechatronics EngineeringHarbin Institute of TechnologyHarbinChina
  2. 2.Japan Mechanical Engineering FacultyNippon Institute of TechnologySaitama Pref.Japan

Personalised recommendations