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Journal articles on the topic 'Advanced ceramics machining'

Author: Grafiati
Published: 4 June 2021
Last updated: 1 February 2022

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1

Jahanmir, S., and L. K. Ives. "Machining of advanced ceramics." Tribology International 28, no. 6 (September 1995): 415–20. http://dx.doi.org/10.1016/0301-679x(94)00009-f.

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2

Manna, Alakesh, and Amandeep Kundal. "Micro Machining of Nonconductive Al2O3 Ceramic on Developed TW-ECSM Setup." International Journal of Manufacturing, Materials, and Mechanical Engineering 1, no. 2 (April 2011): 46–55. http://dx.doi.org/10.4018/ijmmme.2011040103.

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Advanced ceramic materials are gradually becoming very important for their superior properties such as high hardness, wear resistance, chemical resistance, and high strength to weight ratio. But machining of advanced ceramic like Al2O3-ceramics is very difficult by any well known and common machining processes. Normally, cleavages and triangular fractures generate when machining of these materials is done by traditional machining methods. It is essential to develop an efficient and accurate machining method for processing advanced ceramic materials. For effective machining of Al2O3-ceramics, a traveling wire electrochemical spark machining (TW-ECSM) setup has been developed. The developed TW-ECSM setup has been utilized to machine Al2O3 ceramic materials and subsequently test results are utilized to analyze the machining performance characteristic. Different SEM photographs show the actual condition of the micro machined surfaces. The practical research analysis and test results on the machining of Al2O3 ceramics by developed TWECSM setup will provide a new guideline to the researchers and manufacturing engineers.
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3

Gorin, Alexander, and M. Mohan Reddy. "Advanced Ceramics: Some Challenges and Solutions in Machining by Conventional Methods." Applied Mechanics and Materials 624 (August 2014): 42–47. http://dx.doi.org/10.4028/www.scientific.net/amm.624.42.

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The lecture discusses various machining methods of advanced ceramics, their performances and limitations. These methods include both conventional turning, grinding and milling operations and some selected from the category of non-traditional machining processes like electrical discharge machining, laser assisted milling, abrasive water jet and other are presented as well. Special consideration is given to machinable glass ceramic and aluminum nitride ceramic representing structural ceramics due to their wide range of applications and attractive properties
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4

Zhang, Feng Lian. "Machining Mechanism of Abrasive Water Jet on Ceramics." Key Engineering Materials 426-427 (January 2010): 212–15. http://dx.doi.org/10.4028/www.scientific.net/kem.426-427.212.

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Engineering ceramics feature resistance to high temperature, corrosion, wear and hot impact. However, it is difficult to machine this material in conventional machining methods because of its high hardness and brittleness as well as inconductivity, thus restricting its application area. In recent years, more and more importance has been attached to the new machining method of engineering ceramics, i.e. abrasive water-jet. Feature high efficiency and low cost, the method can be used to process the products of complex shape. However, abrasive water-jet machining of advanced ceramics is a very complex process. The effect of machining on brittle materials, and advanced ceramic materials in particular, have not yet been very well understood. The present research investigates the effect of abrasive water-jet machining on ceramics. The study will increase the general understanding of the machining phenomena for more successful application of abrasive water-jet machining on brittle materials.
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Zeng, Wei Min, Xi Peng Xu, and Zhi Jian Pei. "Rotary Ultrasonic Machining of Advanced Ceramics." Materials Science Forum 532-533 (December 2006): 361–64. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.361.

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Rotary ultrasonic machining (RUM) is one of the cost-effective machining methods for advanced ceramics, which is a hybrid machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining (USM). This paper presents an overview of the investigations on RUM of advanced ceramics. The issues about the material removal mechanisms, process modeling, material removal rate, and tool wear in RUM are reviewed. Directions of future research on RUM are also presented.
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6

Bilal, A., A. Rashid, C. Liu, M. P. Jahan, D. Talamona, and A. Perveen. "Powder Mixed Micro Electro Discharge Machining of Aluminium Nitride Ceramic." MATEC Web of Conferences 303 (2019): 06002. http://dx.doi.org/10.1051/matecconf/201930306002.

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Advanced ceramic materials possess superior mechanical characteristics in terms of hardness, wear resistance, fracture toughness and flexural strength. However, these materials experience machining limitations due to their hardness. Machining process of such materials requires high cutting forces and results in high tool wear. Electro- discharge machining (EDM) can be considered as an alternative machining process for advanced ceramics, since this technique is a non-contact machining process, it does not involve high cutting forces but experiences moderate tool wear. However, EDM requires materials to have certain level of electrical conductivity, therefore, non-conductive and semi-conductive ceramic materials experience challenges during machining process. Assisting Electrode Method was suggested as a solution for machining of non-conductive ceramics by EDM. In this method, conductive layer is applied on top of non-conductive ceramics and thus workpiece can be machined by EDM process using residual conductive layer. In this study, coating consisting of three layers, where silver nanoparticles were sandwiched between two layers of silver and copper on top, was used as assisting electrode to machine Aluminium Nitride (AlN) ceramics by silver nanoparticles mixed micro-EDM. Successful machining of AlN was demonstrated and blind micro hole with higher than three aspect ratio was achieved.
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7

Tian, Xin Li, Jun Fei Yang, Chao Liu, and Bao Guo Zhang. "Research Progress of Advanced Machining Technologies for Engineering Ceramics." Advanced Materials Research 69-70 (May 2009): 359–63. http://dx.doi.org/10.4028/www.scientific.net/amr.69-70.359.

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Based on the comprehensive summary of latest research achievements of Laser and EDM technologies in home and abroad, the other advanced machining technologies is summarized briefly, such as Ultrasonic Wave, Microwave machining techniques and their composite machining technologies, as well as High-speed (Super High-speed) Grinding, ELID Grinding and Interface Thermal Chemistry Reaction Aided Machining technologies developed on the basis of traditional grinding technology. At last, it is forecasted that the necessary direction of advanced technologies used for ceramics is combinatorial machining technologies of two or more kinds of advanced technologies.
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8

Watanabe, Keiichiro, Tomonori Takahashi, Tomoki Nagae, and Hiroyuki Tsuji. "Precision Forming and Machining Technologies for Ceramic-Based Components." International Journal of Automation Technology 12, no. 5 (September 5, 2018): 739–49. http://dx.doi.org/10.20965/ijat.2018.p0739.

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Structural ceramics components for industrial use are classified under two categories: one that is originally designed for ceramics (Ceramic Origin), and the other that is originally designed for metals and subsequently replaced with ceramics because of their improved hardness and resistance to both heat and corrosion (Metal Origin). Ceramic insulators for power lines and catalytic substrates used to control automotive emissions in gasoline engines are “Ceramic Origin” components. As ceramics are difficult to machine, a precision mold has been used in the forming process to minimize the machining volume in the case of “Ceramic Origin” components. Meanwhile, ceramic turbo charger rotors and valves for automotive engines are “Metal Origin” components, which not only require durability under severe operating conditions but also severe dimensional accuracy, similar to metal parts. These components have been derived from extensive R&D efforts in materials and process technologies for ceramic gas turbines, which have been implemented in the majority of advanced countries since the 1970s. This paper includes some examples of precision forming and machining technologies for both types of ceramic components developed by NGK Insulators, Ltd., and highlight their issues. Finally, the possibility of new types of ceramic-based components will be introduced.
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9

Deng, Qian Fa, Ping Zhao, Bing Hai Lv, Ju Long Yuan, and Zhi Wei Wang. "Process Parameters Influence on Semi-Fixed Abrasive Tool Wear." Advanced Materials Research 325 (August 2011): 251–56. http://dx.doi.org/10.4028/www.scientific.net/amr.325.251.

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Abrasive machining is an important process for the manufacturing of advanced ceramics. The demand for advanced ceramics with better quality and higher efficiency presents tremendous challenges for abrasive tools in the advanced ceramics industry. The concept of semi-fixed abrasive machining with a newly developed semi-fixed abrasive tool (SFAT) as machining tool is put forward. This paper presents an experimental investigation for SFAT wear into course of machining single crystal silicon with SFAT. Process parameters (water flow, load and velocity) influencing the SFAT wear are analyzed. Influencing factor of SFAT wear in processing course has been clearly demonstrated.
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10

Kuruc, Marcel, Martin Kusý, Vladimír Šimna, and Jozef Peterka. "Influence of Machining Parameters on Surface Topography of Cubic Boron Nitride at Rotary Ultrasonic Machining." Key Engineering Materials 686 (February 2016): 180–85. http://dx.doi.org/10.4028/www.scientific.net/kem.686.180.

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Poly-crystalline cubic boron nitride (PCBN) is one of the hardest known material. Therefore only advanced methods are able to treat such material. Advanced machining methods, proper for machining of hard and brittle materials (such as glass and ceramics) include rotary ultrasonic machining (RUM). This method should achieve high precision and low surface roughness (at least during machining of materials such as ceramics). Achievable roughness is affected by machined material and machining parameters. This contribution investigates influence of machining parameters, such as cutting speed and feed rate, on resultant surface roughness during machining of PCBN by rotary ultrasonic machining.
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11

Frei, H., and G. Grathwohl. "Microstructure and strength of advanced ceramics after machining." Ceramics International 19, no. 2 (January 1993): 93–104. http://dx.doi.org/10.1016/0272-8842(93)90081-2.

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12

Silva, Olivério Moreira Macedo, José Vitor C. Souza, Maria do Carmo de Andrade Nono, G. V. Martins, M. V. Ribeiro, and João Paulo Barros Machado. "Development of Ceramic Cutting Tools for Future Application on Dry Machining." Materials Science Forum 660-661 (October 2010): 724–29. http://dx.doi.org/10.4028/www.scientific.net/msf.660-661.724.

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Advanced ceramic materials constitute a mature technology with a very broad base of current and potential applications and a growing list of material compositions. Within the advanced ceramics category, silicon nitride based ceramics are wear-resistant, corrosion- resistant and lightweight materials, and are superior to many materials with regard to stability in high-temperature environments. Because of this combination the silicon nitride ceramics have an especially high potential to resolve a wide number of machining problems in the industries. Presently the Si3N4 ceramic cutting tool inserts are developed using additives powders that are pressed and sintered in the form of a cutting tool insert at a temperature of 1850 oC using pressureless sintering. The microstructure of the material was observed and analyzed using XRD, SEM, and the mechanical response of this array microstructure was characterized for hardness Vickers and fracture toughness. The results show that Si3N4/20 wt.% (AlN and Y2O3) gives the best balance between hardness Vickers and fracture toughness. The Si3N4/15 wt.% (AlN and Y2O3) composition allows the production of a very fine-grained microstructure with low decreasing of the fracture toughness and increased hardness Vickers. These ceramic cutting tools present adequate characteristics for future application on dry machining.
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13

Kibria, G., B. Sharma, B. Doloi, and B. Bhattacharyya. "Experimental Investigation into Pulsed Nd:YAG Laser Micro-Turning of Engineering Ceramics." Advanced Materials Research 264-265 (June 2011): 1318–23. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1318.

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Laser beam machining (LBM) is the most exciting thermal energy based non-contact type advanced material machining method to process almost whole range of materials. The laser microturning of ceramics are highly demanded in the present industries because of its wide and potential uses in various engineering fields such as automobile, electronics, aerospace, biomedical applications etc. The present paper addresses the basic experimental study of Nd:YAG laser microturning of advanced engineering cylindrical shaped ceramic material to explore the desired laser output responses i.e. depth of cut and surface roughness by varying laser micro-turning process parameters such as lamp current, pulse frequency and rotational speed of workpiece etc.
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14

Ji, Ren Jie, Yong Hong Liu, Chao Zheng, Fei Wang, and Yan Zhen Zhang. "Design of the Tool for End Electrical Discharge Milling and Mechanical Grinding Compound Machining of Engineering Ceramics." Advanced Materials Research 664 (February 2013): 806–10. http://dx.doi.org/10.4028/www.scientific.net/amr.664.806.

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Advanced engineering ceramics have been widely used in modern industry due to their excellent physical and chemical properties. However, they are difficult to machine due to their high hardness and brittleness. End electrical discharge milling and mechanical grinding compound machining method is employed to machine SiC ceramic in this paper. The process is able to effectively machine a large surface area on SiC ceramic. Furthermore, the tool for the compound machining of SiC ceramic is designed based on the goal of the higher material removal rate, the lower tool wear, and the better machined surface quality. The results show that with the designed tool for the compound machining, the higher material removal rate, the lower tool wear, and the better machined surface quality can be obtained.
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15

Hara, Keisuke, Hiromi Isobe, Shuichi Chiba, and Keiko Abe. "A Study of Ultrasonically Assisted Fly Cutting for High Precision Machining Hard Brittle Materials." Advanced Materials Research 126-128 (August 2010): 252–57. http://dx.doi.org/10.4028/www.scientific.net/amr.126-128.252.

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This paper describes ultrasonically assisted fly cutting for finishing advanced ceramics for hot-press dies used to fabricate glass lenses. Fly cutting can perform shallow machining, which realizes ductile-mode cutting of hard, brittle materials. Ultrasonically assisted machining can increase the critical cutting depth (i.e., the maximum cutting depth for ductile-mode machining of a surface). The technique proposed in this paper combines both techniques and enables precise finishing of advanced ceramics at a high machining efficiency. Ultrasonic assisted fly cutting was found to reduce tool fracture and improve the finished surface quality compared with conventional fly cutting.
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16

Li, Song Hua, Ming Hao Feng, Xue Li, Yu Hou Wu, and Xiao Lin Jin. "Research on Application of Advanced Ceramics in Machine Tool Spindles." Advanced Materials Research 753-755 (August 2013): 1448–52. http://dx.doi.org/10.4028/www.scientific.net/amr.753-755.1448.

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One important demand on spindle systems in modern machine tools is to realize higher rotational speed in order to increase the machining efficiency. So, the low rotational inertia and high fundamental natural frequency are indispensable. Because of advanced ceramics' extraordinary physical properties such as high hardness, low thermal expansion, light weight, abrasion resistant and good chemical and thermal stability, it accommodates very well the high-speed and precision requirements of machine tool spindles. In this study, a high-speed ceramic spindle system equipped with high-performance structural ceramic shaft and fully-ceramic ball bearings was designed and developed. The high-speed ceramic motorized spindle prototype was assembled with high precision successfully, and its performance test and analysis were finished. The test results show that ceramic motorized spindle can reduce the high-speed rotational centrifugal force and inertia force and increase the stiffness and rotation accuracy of spindle-bearing system greatly.
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17

Sánchez, J. A., I. Cabanes, L. N. López de Lacalle, and A. Lamikiz. "Development of Optimum Electrodischarge Machining Technology for Advanced Ceramics." International Journal of Advanced Manufacturing Technology 18, no. 12 (December 2001): 897–905. http://dx.doi.org/10.1007/pl00003958.

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18

Zheng, Jian Xin, and Jia Wen Xu. "Basic Experimental Research on the NC-Contour Evolution Ultrasonic Assisted Grinding Ceramic Blade Surface." Key Engineering Materials 359-360 (November 2007): 369–273. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.369.

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Ultrasonic machining is a practical process for advanced ceramic machining. Usually, ceramics with complex surfaces are machined with two common ultrasonic assisted contour machining methods, which may be classified as surface/point contact machining mode. While these methods are not suitable to machine some complex surfaces such as blade surface, so an ultrasonic assisted contour machining method using a simple shaped diamond grinding wheel to machine ceramic blade surface is presented, which is named as Numerical Control-Contour Evolution Ultrasonic Assisted Grinding (NC-CEUAG) method. In the NC-CEUAG process, the contour evolution motion of the grinding wheel is controlled by the NC system and the blade surface is the enveloping surface formed by the grinding wheel’ cutting edges when they cut into the ceramic specimen. In this paper, the relative motion between the grinding wheel and the specimen in the process of NC-CEUAG ceramic blade surface is analyzed. The mathematical models of ruled surfaces are constructed. The ceramic blades with ruled surface are machined with selected machining parameters on the retrofitting NC-CEUAG machine tool.
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19

Ojha, Nirdesh, Florian Zeller, Claas Mueller, and Holger Reinecke. "Study on the Effect of Tool Polarity and Tool Rotation during EDM of Non-Conductive Ceramics." Advanced Materials Research 941-944 (June 2014): 2127–33. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.2127.

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The ability to machine advanced ceramic materials such as ZrO2, SiC, and AlN is of high interest for various industries because of the extraordinary material properties that these ceramics possess. Once sintered, these ceramics are characterized with high mechanical strength, high thermal stability and high chemical inertness. Therefore it is extremely difficult to machine these ceramics with dimensions in few microns using traditional techniques. Electrical discharge machining (EDM) is an electro-thermal machining process used to structure conductive materials. By applying a conductive layer on top of the non-conductive material, the EDM process can also be used to machine the non-conductive material. This paper presents a study on the effect of tool polarity and tool rotation on the material removal rate and electrode wear ratio during the EDM process of non-conductive SiC, ZrO2 and AlN ceramics. The reasons for the variation in the material removal rates among the different ceramics are examined by comparing the material properties. Relatively lower value of flexural strength, fracture toughness and melting temperature is the reason for AlN ceramic to have the higher MRR than SiC and ZrO2 ceramics.
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20

Andrade, Ana C. Balarin de, Paulo R. Aguiar, Martin A. Aulestia Viera, Felipe A. Alexandre, Pedro Oliveira Junior, and Fabio R. L. Dotto. "Monitoring of the Ceramic Kerf During the Laser Cutting Process through Piezoelectric Transducer." Proceedings 42, no. 1 (November 14, 2019): 44. http://dx.doi.org/10.3390/ecsa-6-06529.

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Advanced ceramics are widely used in industry due to their unique properties. However, the machining of ceramic components by conventional methods is difficult due to their high level of hardness and brittleness. In this sense, laser beam machining (LBM) is presented as an alternative to conventional methods, enabling the machining of workpieces through more accurate and less invasive techniques. Despite the advantages of laser machining, the process still needs to be studied in detail, as advanced ceramic machining is considered a stochastic process. Thus, real-time monitoring systems are required in order to optimize the ceramic laser machining. Therefore, this paper proposes a novel method for monitoring the cutting kerf in the laser cutting process of ceramic components using a low-cost piezoelectric transducer (PZT) and digital signal processing. Tests were performed on the surface of an alumina ceramic workpiece under different machining conditions. The cutting kerf was measured by a digital microscope and the raw signals from the PZT transducer were collected at a sampling rate of 2 MHz. Time domain and frequency domain analyses were performed in order to find a frequency band that best correlates with the process conditions. Finally, a linear regression was calculated in order to correlate the PZT signal and the measured kerf. The results showed that the piezoelectric transducer was sensitive to the acoustic activity generated during the process, allowing the real-time monitoring of the cutting kerf. Thus, the approach proposed in this paper can be used efficiently in the monitoring of the laser cutting process.
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21

Deng, Qian Fa, Ju Long Yuan, Zhi Wei Wang, Dong Hui Wen, and Xun Lv. "An Investigation to Semi-Fixed Abrasives Plate Characteristics." Key Engineering Materials 416 (September 2009): 563–67. http://dx.doi.org/10.4028/www.scientific.net/kem.416.563.

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The most typical example of hard and brittle material is advanced ceramics, for its ultra-precision machining difficulty and wide applications, now it becomes a focus of attention. Semi-fixed abrasive plate (SFAP) is newly developed for preventing larger particles from doing workpiece surface damage in machining advanced ceramics, for larger particles from grain size dispersion or from outside of processing area could bring uneven load distribution on processing region of advanced ceramics. In this paper, Shearing strength, surface hardness and Young’s modulus as characteristics of SFAP are investigated. They were influenced by Grain size and abrasive weight ratio are analyzed and discussed, as well as the qualitative estimation of these influences on the characteristics of SFAP are deduced.
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22

Kuruc, Marcel, and Jozef Peterka. "Rotary Ultrasonic Machining of Poly-Crystalline Cubic Boron Nitride." Research Papers Faculty of Materials Science and Technology Slovak University of Technology 22, no. 341 (December 1, 2014): 103–8. http://dx.doi.org/10.2478/rput-2014-0015.

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Abstract Poly-crystalline cubic boron nitride (PCBN) is one of the hardest material. Generally, so hard materials could not be machined by conventional machining methods. Therefore, for this purpose, advanced machining methods have been designed. Rotary ultrasonic machining (RUM) is included among them. RUM is based on abrasive removing mechanism of ultrasonic vibrating diamond particles, which are bonded on active part of rotating tool. It is suitable especially for machining hard and brittle materials (such as glass and ceramics). This contribution investigates this advanced machining method during machining of PCBN.
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23

Baghel, Rupali. "The Scope of Machining of Advanced Ceramics by ElectroDischarge Machining and Its Hybrid Variants." International Journal of Advanced Materials Manufacturing and Characterization 8, no. 2 (August 1, 2018): 87–101. http://dx.doi.org/10.11127/ijammc2018.09.04.

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24

Singh, Ravi Pratap, and Sandeep Singhal. "Experimental investigation of machining characteristics in rotary ultrasonic machining of quartz ceramic." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 232, no. 10 (August 3, 2016): 870–89. http://dx.doi.org/10.1177/1464420716653422.

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Quartz ceramic has been well observed as one of the highly demanded advanced ceramics which is receiving enlarging industrial approbation owing to its excellent and superior properties. However, its fruitful processing with traditional and non-traditional machining methods is still a challenge. The current article has aimed to experimentally investigate the influence of several process variables, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power on machining characteristics of interest, i.e. chipping size, and material removal rate in rotary ultrasonic machining of quartz ceramic. Response surface methodology has been employed to design the experiments and the variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominating brittle fracture that caused removal of material along with the slighter plastic deformation in rotary ultrasonic machining of quartz ceramic. The soundness and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are, 0.6437 mm3/s and 1.3326 mm, respectively, with the combined desirability index value of 0.949.
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Reddy, Moola Mohan, Alexander Gorin, and Khaled A. Abou-El-Hossein. "Development of Cutting Force Model of Aluminum Nitride Ceramic Processed by Micro End Milling." Applied Mechanics and Materials 87 (August 2011): 223–29. http://dx.doi.org/10.4028/www.scientific.net/amm.87.223.

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Advanced ceramics are difficult to do machining due to brittle nature. High cutting forces will generate in the machining, which will affect the surface integrity of final product. Selection of proper machining parameters is important to obtain less cutting force. The present work deals with the study and development of a cutting force prediction model in end milling operation of Aluminum Nitride ceramic. The cutting force equation developed using Response Surface Methodology (RSM) to analyze the effect of Spindle speed, feed rate and axial depth of cut. The cutting tests were carried under dry condition using two flute square end micro grain carbide end mills.
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Kuruc, Marcel, Juraj Vagovský, and Jozef Peterka. "Influence of Machining Parameters on Machine Tool Loads at Rotary Ultrasonic Machining of Cubic Boron Nitride." Key Engineering Materials 686 (February 2016): 155–60. http://dx.doi.org/10.4028/www.scientific.net/kem.686.155.

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Poly-crystalline cubic boron nitride (PCBN) is one of the hardest known material. Therefore only advanced methods are able to treat such material. Advanced machining methods, proper for machining of hard and brittle materials (such as glass and ceramics) include rotary ultrasonic machining (RUM). However, high hardness of workpiece cause higher loads and it could negatively affect achievable accuracy and surface topography. Machine loads are affected by both: machined material and machining parameters. This contribution investigates influence of machining parameters, such as spindle speed, feed rate and depth of cut, on loads of machine tool during machining of PCBN by rotary ultrasonic machining.
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27

Fan, Hong Wei, Bing Hai Lv, Ju Long Yuan, Q. F. Deng, and W. F. Yao. "Fillers and Dissolvent in Porous Self-Generating Fine Super-Hard Abrasive Tool." Advanced Materials Research 135 (October 2010): 398–403. http://dx.doi.org/10.4028/www.scientific.net/amr.135.398.

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In order to obtain low surface damage and high machining efficiency for advanced ceramics, overcome clogging and dressing difficulties of traditional metal bonded super-hard abrasive, a novel fine super-hard abrasive with porous self-generating ability is proposed in this paper. And the matching of filler and dissolvent in abrasive are studied. Soluble filler is a key technology of porous self-generating fine super-hard abrasive. In this paper, metal, metal oxide and non-metallic oxide are respectively used as soluble fillers. Results of the experimental shows: In metal bonded super-hard abrasive, metal, metal oxide and non-metallic oxide as soluble filler are feasible, correspondingly, FeCl3 solution, aqueous solution and weak alkaline solution are used as dressing dissolvent, respectively. It can be met the requirement of high precision machining for advanced ceramic materials, hard and brittle machining materials.
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Li, Zhi Hong, Y. H. Zhang, Bing Han, and Y. M. Zhu. "Grinding of TZP/Al2O3 Composite with Vitrified CBN Wheels." Key Engineering Materials 336-338 (April 2007): 1455–57. http://dx.doi.org/10.4028/www.scientific.net/kem.336-338.1455.

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Advanced ceramics has many advantages and great potential of application, but its high machining cost resulted from its high hardness and brittleness limited its application. Grinding with superabrasives is the most suitable and effective way for machining of advanced ceramics. Grinding with vitrified bond CBN wheels is a developing direction of high efficient grinding for engineering ceramics. Grinding of the promising composite ceramics of TZP/Al2O3 with vitrified bond CBN grinding wheels was investigated in this paper. The results showed that higher material removal rates and satisfactory surface finish were achieved, CBN wheels with coarser grit size or with higher CBN concentration had higher grinding ratio. G-ratio increased with the increasing of wheel speed.
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29

Ming, Wuyi, Haojie Jia, Hongmei Zhang, Zhen Zhang, Kun Liu, Jinguang Du, Fan Shen, and Guojun Zhang. "A comprehensive review of electric discharge machining of advanced ceramics." Ceramics International 46, no. 14 (October 2020): 21813–38. http://dx.doi.org/10.1016/j.ceramint.2020.05.207.

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30

Deng, Qian Fa, Dong Hui Wen, Ju Long Yuan, and Feng Chen. "Examination to Machining Characteristics of Semi-Fixed Abrasive Plate during the Lapping Process." Advanced Materials Research 69-70 (May 2009): 108–12. http://dx.doi.org/10.4028/www.scientific.net/amr.69-70.108.

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The most typical example of hard and brittle material is advanced ceramics, for its ultra-precision machining difficulty and wide applications, now it becomes a focus of attention. Semi-fixed abrasive plate (SFAP) is newly developed tool for machining advanced ceramics; As a result of SFAP abrasion, a gradual change takes place in the SFAP topography to influence on machining results and productivity. The paper shows experiment procedures to evaluate SFAP abrasion rate and workpiece material removal. The results of experiments are discussed and analyzed, it indicates that wet status of SFAP have great influences on the removal rate and SFAP abrasion. Compared with dry status of SFAP, wet status of SFAP can achieve higher processing efficiency.
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31

Guo, Yong Feng, Guan Qun Deng, Ji Cheng Bai, and Ze Sheng Lu. "Electrical Discharge Machining (EDM) Phenomena of Insulating ZrO2 Ceramics with Assisting Electrode." Key Engineering Materials 375-376 (March 2008): 313–17. http://dx.doi.org/10.4028/www.scientific.net/kem.375-376.313.

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Advanced engineering ceramics are more and more widely employed in modern industries because of their excellent mechanical properties such as high hardness, high compressive strength, high chemical and abrasive resistance. These properties limited the machining to the insulated ceramics. This paper investigates the electrical discharge machining (EDM) of ZrO2-based ceramics by assisting electrode method. The theory of assisting electrode method is introduced. The machining phenomena under different electrical parameters were studied. The material removal mechanisms change with the increase in the power of single pulse. Some work-pieces have been machined successful through the assisting electrode method.
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Xu, Chong Hai, and H. Y. Wang. "Design of Ceramic Composite Based on the Impact Resistance and its Machining Application." Key Engineering Materials 336-338 (April 2007): 2487–89. http://dx.doi.org/10.4028/www.scientific.net/kem.336-338.2487.

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An optimum model for the compositional design of advanced ceramic composites is built based on the impact resistance. The relative impact modulus IM0 is defined as an index for the characterization of impact resistance of brittle ceramics. Computer aided optimum technique is used to get the optimum compositions of the material. Results show that the material can be expected to have the highest impact resistance which is nearly 86% higher than that of the pure alumina when the volume fraction of Al2O3, SiC and Ti(C,N) is 72.3%, 14.8% and 12.9%, respectively. An advanced SiC/Ti(C,N)/Al2O3 ceramic composite is then fabricated according to the optimum results. When used as cutting tools, its impact fracture resistance is approximately 71%-76% higher than that of the pure alumina ceramic in the machining of hardened carbon steel. The increment coincides well with that predicted directly from the optimum model. It suggests that the method is feasible in the design and fabrication of ceramic composites especially for machining application.
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33

Liu, Li Ping, Bin Lin, and Feng Zhou Fang. "Monitoring of Tool Wear in Rotary Ultrasonic Machining of Advanced Ceramics." Advanced Materials Research 314-316 (August 2011): 1754–59. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.1754.

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Tool wear and failure monitoring has raised quite a lot of interests among researchers and has consequently been studied in a number of research projects by a number of research organisations. However, few researchers monitored tool wear in rotary ultrasonic machining (RUM) using various sensors. This paper, for the first time in literature, presents an experimental monitoring on tool wear in RUM of silicon carbide (SiC) using accelerometer, force and acoustic emission sensors. A digital microscope was used to observe the actual tool wear during the experiment. After describing the experimental procedures, it presents and discusses the results on tool wear and acceleration signal, force signal and acoustic signal in RUM of SiC
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34

Farooqui, Mohammed Naser, and Nilesh G. Patil. "A perspective on shaping of advanced ceramics by electro discharge machining." Procedia Manufacturing 20 (2018): 65–72. http://dx.doi.org/10.1016/j.promfg.2018.02.009.

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35

Sabur, Abdus, Abdul Moudood, Mohammad Yeakub Ali, and Mohammad Abdul Maleque. "Effect of Micro-EDM Parameters on Material Removal Rate of Nonconductive ZrO2 Ceramic." Applied Mechanics and Materials 465-466 (December 2013): 1329–33. http://dx.doi.org/10.4028/www.scientific.net/amm.465-466.1329.

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Micro-electro discharge machining (micro-EDM) technique, an advanced noncontact machining process, is used for structuring of nonconductive ZrO2 ceramic. In this study copper foil as a conductive layer is adhered on the workpiece surface to initiate the sparks and kerosene is used as dielectric for creation of continuous conductive pyrolytic carbon layer on the machined surface. Voltage (V) and capacitance (C) are considered as the parameters to investigate the process capability of machining parameters in continuous micro-EDM of ZrO2. Different voltage pulses are studied to examine the causes of lower material removal rate (MRR) in micro-EDM of nonconductive ceramics. The results showed that in micro-EDM of ZrO2 MRR increases with the increase of voltage and capacitance initially, but decreases at higher values and no significant materials are removed at capacitances higher than 1nF.
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36

Suzuki, Hirofumi, and Kazuhito Ohashi. "Special Issue on Advanced Abrasive Process Technologies." International Journal of Automation Technology 13, no. 6 (November 5, 2019): 721. http://dx.doi.org/10.20965/ijat.2019.p0721.

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The demand for high-precision and high-efficiency machining of hard ceramics such as silicon carbide (SiC) for semiconductors and hardened steel for molding dies has significantly increased for power devices in automobiles, optical devices, and medical devices. Certain types of hard metals can be machined by deterministic precision-cutting processes. However, hard and brittle ceramics, hardened steel for molds, or semiconductor materials have to be machined by precision abrasive technologies such as grinding, polishing, and ultrasonic vibration technologies with diamond super abrasives. The machining of high-precision components and their molds/dies by abrasive processes is much more difficult owing to their complex and nondeterministic nature as well as their complex textured surface. Furthermore, high-energy processes with UV lasers and IR lasers, and ultrasonic vibration can be used to assist abrasive technologies for greater precision and efficiency. In this sense, precision grinding and polishing processes are primarily used to generate high-quality and functional components usually made of hard and brittle materials. The surface quality achieved by precision grinding and polishing processes becomes more important to reduce processing time and costs. This special issue features seven research papers on the most recent advances in precision abrasive technologies for hard materials. These papers cover various abrasive machining processes such as grinding, polishing, ultrasonic-assisted grinding, and laser-assisted technologies. We deeply appreciate the careful work of all the authors and thank the reviewers for their incisive efforts. We also hope that this special issue will encourage further research on abrasive technologies.
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37

Guo, Yong Feng, Ji Cheng Bai, Guan Qun Deng, and Ze Sheng Lu. "High Speed Wire Electrical Discharge Machining (HS-WEDM) Phenomena of Insulating Si3N4 Ceramics with Assisting Electrode." Key Engineering Materials 339 (May 2007): 281–85. http://dx.doi.org/10.4028/www.scientific.net/kem.339.281.

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Advanced engineering ceramics are more and more widely employed in modern industries because of their excellent mechanical properties such as high hardness, high compressive strength, high chemical and abrasive resistance. This paper investigates the high speed wire electrical discharge machining (HS-WEDM) of Si3N4-based ceramics by assisting electrode method. The theory of assisting electrode method is introduced. The machining phenomena under different electrical parameters were studied and the optimized machine pulse width was got. The material removal mechanisms change with the increase in the power of single pulse.
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38

Singh, Ravi Pratap, and Sandeep Singhal. "Experimental study on rotary ultrasonic machining of alumina ceramic: Microstructure analysis and multi-response optimization." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 232, no. 12 (June 28, 2016): 967–86. http://dx.doi.org/10.1177/1464420716657370.

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Excellent and superior properties of alumina ceramic make it a one of the highly demanded advanced ceramics in the present competitive scenario of manufacturing and industrial applications. However, its effective and economic processing is still a challenge. The present article has targeted to experimentally investigate the influence of several process variables, namely spindle speed, feed rate, coolant pressure, and ultrasonic power on different machining performances, i.e. surface roughness, and chipping thickness. Response surface methodology has been employed to design the experiments. Microstructure of the machined samples has been evaluated and analyzed through scanning electron microscope. This analysis has revealed and confirmed the presence of plastic deformation of work surface that caused the material removal along with the dominated brittle fracture in the processing of alumina ceramic with rotary ultrasonic machining. The multi-response optimization of machining responses has been done by using desirability approach. At the optimized parametric setting, the obtained experimental values for surface roughness and chipping thickness are found to be 0.215 µm and 0.159 mm, respectively.
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Zeng, W. M., Z. C. Li, Z. J. Pei, and C. Treadwell. "Experimental observation of tool wear in rotary ultrasonic machining of advanced ceramics." International Journal of Machine Tools and Manufacture 45, no. 12-13 (October 2005): 1468–73. http://dx.doi.org/10.1016/j.ijmachtools.2005.01.031.

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40

Modi, Manoj, and Gopal Agarwal. "Design, Development & Experimental Investigation of Electro-Discharge Diamond Surface Grinding of Ti-6Al-4V." Advanced Materials Research 418-420 (December 2011): 1478–81. http://dx.doi.org/10.4028/www.scientific.net/amr.418-420.1478.

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Abstract: Ti-6Al-4V are used extensively in aerospace, medical, marine and surgical implants etc. but it is hard to machine. Machining of advanced difficult-to-machine very hard materials (Ti-6Al-4V, composites and ceramics) is a big challenge. By conventional machining processes, their machining is not only costly but results in poor surface finish and shorter tool life. To meet these challenges, new hybrid machining process (HMP) has been developed. This article is focused on hybrid machining process comprising of conventional surface grinding along with electro-discharge machining between the periphery of metal bonded diamond grinding wheel and flat rectangular shape workpiece. This process has the advantage of shaping advance engineering materials and difficult-to- machine very hard materials. The experimental investigations of various input parameters like wheel RPM, duty factor, current and pulse on-time on material removal rate of Ti-6Al-4V in EDDSG process have been reported here on newly self designed & fabricated set up. Keywords: Electro-Discharge Diamond Surface Grinding (EDDSG), Hybrid Machining Process (HMP), Ti-6Al-4V.
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41

Jiao, Yue, W. J. Liu, Z. J. Pei, X. J. Xin, and C. Treadwell. "Study on Edge Chipping in Rotary Ultrasonic Machining of Ceramics: An Integration of Designed Experiments and Finite Element Method Analysis." Journal of Manufacturing Science and Engineering 127, no. 4 (December 26, 2004): 752–58. http://dx.doi.org/10.1115/1.2034511.

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Rotary ultrasonic machining (RUM) is a relatively low cost and environmentally benign process for machining of advanced ceramics. Much effort has been made to theoretically and experimentally investigate material removal rate, surface roughness, and tool wear in RUM. However, there is no report on systematic study of edge chipping in RUM drilling of ceramics. This paper presents the results of a study on edge chipping in RUM drilling of advanced ceramics. The study is conducted by an integrated approach, combining designed experiments and FEM (finite element method) analysis. The designed experiments will reveal the main effects as well as interaction effects of process variables (spindle speed, ultrasonic power, feedrate, and grit size) on cutting force and chipping thickness. FEM simulations will provide the stress and strain distributions in the workpiece while being drilled by RUM. Furthermore, the relationship between chipping thickness and cutting force obtained from the FEM simulations will be compared with that obtained from the designed experiments.
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42

Meshalkin, Valerii P., and Alexey V. Belyakov. "Methods Used for the Compaction and Molding of Ceramic Matrix Composites Reinforced with Carbon Nanotubes." Processes 8, no. 8 (August 18, 2020): 1004. http://dx.doi.org/10.3390/pr8081004.

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Ceramic matrix composites reinforced with carbon nanotubes are becoming increasingly popular in industry due to their astonishing mechanical properties and taking into account the fact that advanced production technologies make carbon nanotubes increasingly affordable. In the present paper, the most convenient contemporary methods used for the compaction of molding masses composed of either technical ceramics or ceramic matrix composites reinforced with carbon nanotubes are surveyed. This stage that precedes debinding and sintering plays the key role in getting pore-free equal-density ceramics at the scale of mass production. The methods include: compaction in sealed and collector molds, cold isostatic and quasi-isostatic compaction; dynamic compaction methods, such as magnetic pulse, vibration, and ultrasonic compaction; extrusion, stamping, and injection; casting from aqueous and non-aqueous slips; tape and gel casting. Capabilities of mold-free approaches to produce precisely shaped ceramic bodies are also critically analyzed, including green ceramic machining and additive manufacturing technologies.
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43

Konneh, Mohamed. "Diamond Grit Size Prediction in Surface Grinding Silicon Carbide." Advanced Materials Research 576 (October 2012): 539–42. http://dx.doi.org/10.4028/www.scientific.net/amr.576.539.

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High hardness, chemical stability, attractive high temperature wear resistance, low density and strength at elevated temperature are the advantages of ceramics over other materials. These properties have made a number of components made of hard and brittle materials, typically represented by advanced ceramics gained applications in industrial sectors over the past two decades. Nevertheless the benefits due to the salient features of ceramic materials go along with some difficulties with machining in general because of their high values of hardness and very low fracture toughness as compared to other metallic materials and alloys. This paper presents an experiemntal study on identifying the diamond grit size and grinding condition that produced low surface roughness value, Ra and less micro-fractures on ground silicon carbide work-piece material.
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44

Alkhalefah, Hisham. "Precise Drilling of Holes in Alumina Ceramic (Al2O3) by Rotary Ultrasonic Drilling and its Parameter Optimization using MOGA-II." Materials 13, no. 5 (February 27, 2020): 1059. http://dx.doi.org/10.3390/ma13051059.

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Alumina is an advanced ceramic with applications in dental and medical sciences. Since ceramics are hard and brittle, their conventional machining is expensive, arduous, and time-consuming. As rotary ultrasonic machining is among the most adequate and proficient processing techniques for brittle materials like ceramics. Therefore, in this study, rotary ultrasonic drilling (RUD) has been utilized to drill holes on alumina ceramic (Al2O3). This study investigates the effect of key RUD process variables, namely vibration frequency, vibration amplitude, spindle speed, and feed rate on the dimensional accuracy of the drilled holes. A four-variable three-level central composite design (thirty experiments on three sample plates) is utilized to examine the comparative significance of different RUD process variables. The multi-objective genetic algorithm is employed to determine the optimal parametric conditions. The findings revealed that material removal rates depend on feed rate, while the cylindricity of the holes is mostly controlled by the speed and feed rate of the spindles. The optimal parametric combination attained for drilling quality holes is speed = 4000 rpm, feed rate = 1.5 (mm/min), amplitude = 20 (µm), and frequency = 23 (kHz). The validation tests were also conducted to confirm the quality of drilled holes at the optimized process parameters.
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45

Zhao, Ping, Qian Fa Deng, Bing Hai Lv, Wei Hang, Zhi Wei Wang, and Ju Long Yuan. "Investigation of Semi-Fixed Abrasive Plate Wear Characteristics." Advanced Materials Research 126-128 (August 2010): 1029–33. http://dx.doi.org/10.4028/www.scientific.net/amr.126-128.1029.

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In order to reduce or eliminate the surface defects caused by abrasive grains and improve the efficiency of ultra-precision processing, the technique of semi-fixed machining has been proposed for machining advanced ceramics. A semi-fixed abrasive tool (SFAT) has been manufactured; it has performances of semi-fixed machining technique. This document demonstrates wear characteristics of SFAT through experiments of machining silicon wafer. It showed that wet status or dry status of SFAT has greatly influenced wear characteristics of SFAT. Wear characteristic of SFAT presented mostly blockage and little grain-off occurred in dry status; mostly grain-off and little blockage presented in wet status.
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46

Hou, Ya Li, Chang He Li, and Guo Yu Liu. "Investigation into High-Speed/Super-High Speed Grinding." Advanced Materials Research 189-193 (February 2011): 4108–11. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.4108.

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Abrasive machining is a widely employed finishing process for different-to-cut materials such as metals, ceramics, glass, rocks, etc to achieve close tolerances and good dimensional accuracy and surface integrity. High speed and super-high speed abrasive machining technologies are newest developed advanced machining processes to satisfy super-hardness and difficult-to-machining materials machined. In the present paper, high-speed/super-high speed abrasive machining technologies relate to ultra high speed grinding, quick-point grinding, high efficiency deep-cut grinding were analyzed. The efficiency and parameters range of these abrasive machining processes were compared. The key technologies and the newest development and current states of high speed and super-high speed abrasive machining were investigated. It is concluded that high speed and super-high speed abrasive machining are a promising technology in the future.
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47

Fukuzawa, Yasushi, Keiji Yukihiro, and Ken Yamasita. "Machining Properties of Insulating ZrO2 Ceramics Using Porous Copper Electrodes." Key Engineering Materials 443 (June 2010): 608–13. http://dx.doi.org/10.4028/www.scientific.net/kem.443.608.

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Insulating ceramics were considered as machinable material with the electrical discharge machining method using the assisting electrode method, which was proposed and advanced by the authors. The mechanical properties changed with the experimental parameters, including the physical characteristics of the workpiece and the tool electrode. In this research, sintered ZrO2-Y2O3 insulating ceramics were subjected to EDM. To investigate the effects of the porous tool electrode material on the removal rate, the porous copper cylinder material was fabricated by PECS (pulse electric current sintering) method. The relative density changed from 60 to 95 wt%. The suitable machining characteristics could be obtained with a relative density of 85% at the positive electrode polarity. The shape of electrodes was transcribed on the workpiece surface more precisely than the solid copper electrode.
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48

Zeng, Wei Ming, Xi Peng Xu, and Zhi Jian Pei. "Experimental Investigation of Tool Wear in Rotary Ultrasonic Machining of Alumina." Key Engineering Materials 416 (September 2009): 182–86. http://dx.doi.org/10.4028/www.scientific.net/kem.416.182.

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As one of the cost-effective machining methods for advanced ceramics, rotary ultrasonic machining (RUM) has attracted much attention and there exist numerous publications on the process. However, few investigations on tool wear in the RUM process have been reported. This paper, for the first time in literature, presents an experimental observation on tool wear in RUM of alumina. it presents and discusses the results on tool wear in RUM of alumina. It also discusses some practical implications of the findings from this study.
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Bukvic, Gill, Luiz Eduardo de Angelo Sanchez, Carlos Alberto Fortulan, A. A. Fiocchi, and Ioan Demitrius Marinescu. "GREEN MACHINING ORIENTED TO DIMINISH DENSITY GRADIENT FOR MINIMIZATION OF DISTORTION IN ADVANCED CERAMICS." Machining Science and Technology 16, no. 2 (April 2012): 228–46. http://dx.doi.org/10.1080/10910344.2012.673968.

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50

Zeng, Wei Min, Zhi Chao Li, Xi Peng Xu, Zhi Jian Pei, Ju Dong Liu, and Jun Pi. "Experimental Investigation of Intermittent Rotary Ultrasonic Machining." Key Engineering Materials 359-360 (November 2007): 425–30. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.425.

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Rotary ultrasonic machining (RUM) is considered as an effective machining method, which has been utilized to machine hard and brittle materials such as advanced ceramics. In order to improve the hole wall surface quality during RUM, it is important to wash away swarf in the gap between the tool and the workpiece as fast as possible. In this paper, a new machine process – intermittent rotary ultrasonic machining (IRUM) – is introduced for the first time. The cutting force, surface roughness and coolant flow rate in conventional rotary ultrasonic machining (CRUM) process and IRUM process are compared. It is found that compared with CRUM, the output coolant flow rate could be increased significantly by using the IRUM method. It is also found that the surface roughness of workpiece can be improved significantly in IRUM.
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