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Influence of Electrical Resistivity and Machining Parameters on Electrical Discharge Machining Performance of Engineering Ceramics

机译：电阻率和加工参数对工程陶瓷放电加工性能的影响

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摘要

Engineering ceramics have been widely used in modern industry for their excellent physical and mechanical properties, and they are difficult to machine owing to their high hardness and brittleness. Electrical discharge machining (EDM) is the appropriate process for machining engineering ceramics provided they are electrically conducting. However, the electrical resistivity of the popular engineering ceramics is higher, and there has been no research on the relationship between the EDM parameters and the electrical resistivity of the engineering ceramics. This paper investigates the effects of the electrical resistivity and EDM parameters such as tool polarity, pulse interval, and electrode material, on the ZnO/Al2O3 ceramic's EDM performance, in terms of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The results show that the electrical resistivity and the EDM parameters have the great influence on the EDM performance. The ZnO/Al2O3 ceramic with the electrical resistivity up to 3410 Ω·cm can be effectively machined by EDM with the copper electrode, the negative tool polarity, and the shorter pulse interval. Under most machining conditions, the MRR increases, and the SR decreases with the decrease of electrical resistivity. Moreover, the tool polarity, and pulse interval affect the EWR, respectively, and the electrical resistivity and electrode material have a combined effect on the EWR. Furthermore, the EDM performance of ZnO/Al2O3 ceramic with the electrical resistivity higher than 687 Ω·cm is obviously different from that with the electrical resistivity lower than 687 Ω·cm, when the electrode material changes. The microstructure character analysis of the machined ZnO/Al2O3 ceramic surface shows that the ZnO/Al2O3 ceramic is removed by melting, evaporation and thermal spalling, and the material from the working fluid and the graphite electrode can transfer to the workpiece surface during electrical discharge machining ZnO/Al2O3 ceramic.
机译：工程陶瓷由于其优异的物理和机械性能而在现代工业中被广泛使用，并且由于其高硬度和脆性而难以加工。放电加工（EDM）是加工工程陶瓷的合适方法，只要它们具有导电性即可。然而，流行的工程陶瓷的电阻率较高，并且尚未研究EDM参数与工程陶瓷的电阻率之间的关系。本文从材料去除率（MRR），电极磨损率（EWR）方面研究了电阻率和EDM参数（例如工具极性，脉冲间隔和电极材料）对ZnO / Al2O3陶瓷EDM性能的影响。和表面粗糙度（SR）。结果表明，电阻率和电火花加工参数对电火花加工性能有很大的影响。电阻率高达3410Ω·cm的ZnO / Al2O3陶瓷可以通过电火花加工使用铜电极，负的工具极性和较短的脉冲间隔有效加工。在大多数加工条件下，随着电阻率的降低，MRR增大，而SR减小。此外，工具的极性和脉冲间隔分别影响EWR，电阻率和电极材料对EWR产生综合影响。此外，当电极材料发生变化时，电阻率高于687Ω·cm的ZnO / Al2O3陶瓷的电火花加工性能明显不同于电阻率低于687Ω·cm的陶瓷。加工后的ZnO / Al2O3陶瓷表面的微观结构特征分析表明，ZnO / Al2O3陶瓷通过熔化，蒸发和热剥落而被去除，并且在放电加工过程中，工作流体和石墨电极中的材料可以转移到工件表面ZnO / Al2O3陶瓷。

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