Electro-Discharge Machining of Ceramics: A Review

Conventional machining techniques of ceramics such as milling, drilling, and turning experience high cutting forces as well as extensive tool wear. Nevertheless, non-contact processes such as laser machining and electro-discharge machining (EDM) remain suitable options for machining ceramics materials, which are considered as extremely brittle and hard-to-machine. Considering the importance of ceramic machining, this paper attempts to provide an insight into the state of the art of the EDM process, types of ceramics materials and their applications, as well as the machining techniques involved. This study also presents a concise literature review of experimental and theoretical research studies conducted on the EDM of ceramics. Finally, a section summarizing the major challenges, proposed solutions, and suggestions for future research directions has been included at the end of the paper

STUDY OF SLA PRINTING PARAMETERS AFFECTING THE DIMENSIONAL ACCURACY OF THE PATTERN AND CASTING IN RAPID INVESTMENT CASTING

Dimensional accuracy and geometric characteristics of the manufactured parts bear significant importance in product assembly. In Rapid Investment Casting, these characteristics can be affected by the printing parameters of the Additive Manufacturing method used in the pattern production process. Stereolithography is one of the important AM techniques mostly exploited in RIC due to its accuracy, smooth surface, and precision. However, the effect of SLA printing parameters on the dimensional accuracy and geometric characteristics have not been studied thoroughly. This study considers an experimental approach to study the effect of SLA printing parameters such as layer thickness, build angle, support structure density, and support touchpoint size on the dimensional accuracy and geometrical characteristics of the Castable Wax printed patterns and the Al cast parts. Taguchi’s Design of Experiment was used to define the number of experimental runs. SolidCast simulation was used to design the orientation of casting feeder to achieve directional solidification. Coordinate Measuring Machine measurements of deviations in the printed and cast parts were analyzed using the “Smaller-the-better” scheme in the two-step optimization method of Taguchi experiments. Build angle and Layer thickness were identified to be the first and the second most impactful parameters, respectively, affecting both the dimensional and geometric accuracy of Castable Wax patterns and Al cast parts, with optimal values of 0 deg and 0.25 μm, respectively. Both printed and cast parts had twice as many deviations in geometry as in dimensions. The sphere roundness and angularity were found to be the most and least accurate geometric characteristics, respectively. The dimensions in the Z direction were more accurate than in the X-Y directions, showing the smallest size deviations for height measurements and large deviations in the length, width, and diameter of the hole

Modeling of Material Removal Rate and Surface Roughness Generated during Electro-Discharge Machining

This study reports on the numerical model development for the prediction of the material removal rate and surface roughness generated during electrical discharge machining (EDM). A simplified 2D numerical heat conduction equation along with additional assumptions, such as heat effect from previously generated crater on a subsequent crater and instantaneous evaporation of the workpiece, are considered. For the material removal rate, an axisymmetric rectangular domain was utilized, while for the surface roughness, a rectangular domain where every discharge resides at the end of previous crater was considered. Simulated results obtained by solving the heat equation based on a finite element scheme suggested that results are more realistic by considering instantaneous evaporation of the material from the workpiece and the effect of residual heat generated from each spark. Good agreement between our model and previously published data validated the newly proposed models and demonstrate that instantaneous evaporation, as well as residual heat, provide more realistic predictions of the EDM process

THE POST-PROCESSING OF ADDITIVE MANUFACTURED POLYMERIC AND METALLIC PARTS

The traditional manufacturing industry has been revolutionized with the introduction of additive manufacturing which is based on layer-by-layer manufacturing. Due to these tool-free techniques, complex shape manufacturing becomes much more convenient in comparison to traditional machining. However, additive manufacturing comes with its inherent process characteristics of high surface roughness, which in turn effect fatigue strength as well as residual stresses. Therefore, in this paper, common post-processing techniques for additive manufactured (AM) parts were examined. The main objective was to analyze the finishing processes in terms of their ability to finish complicated surfaces and their performance were expressed as average surface roughness (Sa and Ra). The techniques were divided according to the materials they applied to and the material removal mechanism. It was found that chemical finishing significantly reduces surface roughness and can be used to finish parts with complicated geometry. Laser finishing, on the other hand, cannot be used to finish intricate internal surfaces. Among the mechanical abrasion methods, abrasive flow finishing shows optimum results in terms of its ability to finish complicated freeform cavities with improved accuracy for both polymer and metal parts. However, it was found that, in general, most mechanical abrasion processes lack the ability to finish complex parts. Moreover, although most of post-processing methods are conducted using single finishing processes, AM parts can be finished with hybrid successive processes to reap the benefits of different post-processing techniques and overcome the limitation of individual process

Effect of Conductive Coatings on Micro-Electro-Discharge Machinability of Aluminum Nitride Ceramic Using On-Machine-Fabricated Microelectrodes

The objective of this study is to investigate the feasibility of machining micro-holes on the non-conductive Aluminum Nitride (AlN) ceramics using micro-electro-discharge machining (EDM) process by exploiting various coating techniques. Although ceramics possess excellent mechanical properties under compressive load condition and superior thermal properties, machining of microscale features on ceramics remains challenging due to the extreme brittleness associated with ceramics. Due to the involvement of higher cutting force and tool wear issue, conventional machining process appears to be unsuitable for machining ceramics. On the other hand, non-contact and negligible process force associated with EDM process makes it one of the competitive processes for machining of ceramics. A series of experiments were carried out on AlN ceramics using "Assistive Electrode" micro-EDM process with a goal of machining blind micro-holes into the ceramics with the aid of on-machine fabricated copper tungsten tools. It was found that multi-layer coatings of silver and copper with copper tungsten electrode resulted in successful machining with high-aspect-ratio holes during powder mixed micro-EDM of AlN ceramics, while micro-holes with less than one aspect ratio are machined without powder addition to the dielectric. It was also observed that comparatively lower level of discharge energies, i.e., lower value of voltages and capacitances were favorable for successful machining of micro-holes in ceramics, even though it results in significantly higher machining time. Despite of relatively low discharge energy usage in micro-EDM, machined surfaces appear to be very rough. The machined surfaces indicate that melting and evaporation, as well as thermal spalling, are the dominating material removal mechanisms. The machined surfaces contained many thermal cracks and porosity on the surface. The elemental composition analysis confirms the presence of aluminum and nitrogen elements on the machined surface. Finally, by careful selection of machining conditions and assistive electrode, successful machining of micro-holes is possible on the non-conductive ceramic surfaces using the micro-EDM process

Buckling curves of hot rolled H steel sections submitted to fire

Report of the research work at the base of the design equation introduced in Eurocode 3 (EN 1993-1-2) for the stability of steel columns under axial loading or combined axial and bending loading

Reducing meat consumption in Central Asia through 3D printing of plant-based protein—enhanced alternatives—a mini review

3D food printing (3DFP) is emerging as a vital innovation in the food industry’s pursuit of sustainability. 3DFP has evolved to significantly impact food production, offering the capability to create customized, nutritionally balanced foods. Central Asia has a higher than global average level of meat consumption per capita, which might be influenced by its historical and cultural background of nomadism. This dietary trend might potentially result in negative impacts on both the environment and human health outcomes, as it leads to increased greenhouse gas emissions and increased risk of chronic diseases. Reducing meat consumption holds the potential to address these sustainability and health issues. A possible strategy to reduce meat consumption and promote plant-based foods is 3D Food Printing (3DFP), which can rely on plant-protein sources from the region to create appealing and tasty alternatives for these populations. This review summarizes recent studies on plant protein-rich materials for 3DFP as a substitute to meet the growing global demand for meat as well as the 3DFP printing parameters associated with the different plant-based proteins currently used (e.g., lentils, soybeans, peas, and buckwheat). The findings revealed that buckwheat, a dietary staple in Central Asia, can be a promising choice for 3DFP technology due to its widespread consumption in the region, gluten-free nature, and highly nutritious profile

Numerical study of the fire resistance of steel columns in axial compression and uniform bending

This paper investigates the behavior of steel beam‐columns loaded in axial compression and uniform bending at elevated temperatures. The finite element code SAFIR has been used to predict the failure temperature under a determined load (M+N) assuming in a first case that the temperature within the column is uniform and in a second case that a longitudinal thermal gradient exist. The failure loads have then been interpolated and extrapolated to obtain the failure loads at 400, 500, 600, 700, 800 and 900°C. The results obtained under uniform temperature have compared with two analytical formulations, i.e. the one available from the Eurocode 3 part 1.2 (EC3) and the one established after the Buckling Curves in Case of Fire (BCCF) research project. The results of this comparison show that the BCCF formulation provides a slightly more accurate ultimate load when compared to numerical results than the one obtained with the EC3. It has been found that the ultimate load decreases in a similar way as the yield strength coefficient (Kyθ) as the temperature increases. The calculations performed with a longitudinal thermal gradient show that the evolution of the ultimate load as function of temperature follows a similar pattern than the one observed under uniform temperature

New quadrangular shell element in SAFIR

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