Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium
Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces con...
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| Format: | Article |
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MDPI AG
2022-11-01
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| Series: | Technologies |
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| Online Access: | https://www.mdpi.com/2227-7080/10/6/116 |
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| author | Sergey N. Grigoriev Anna A. Okunkova Marina A. Volosova Khaled Hamdy Alexander S. Metel |
| author_facet | Sergey N. Grigoriev Anna A. Okunkova Marina A. Volosova Khaled Hamdy Alexander S. Metel |
| author_sort | Sergey N. Grigoriev |
| collection | DOAJ |
| description | Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces contact loads and wear of cutting tools. However, most of the published works are related to the electrical discharge machining of alumina in hydrocarbons, which creates risks for the personnel and equipment due to the formation of chemically unstable dielectric carbides (methanide Al<sub>3</sub>C<sub>4</sub> and acetylenide Al<sub>2</sub>(C<sub>2</sub>)<sub>3</sub>). An alternative approach for wire electrical discharge machining Al<sub>2</sub>O<sub>3</sub> in the water-based dielectric medium using copper tape of 40 µm thickness and TiO<sub>2</sub> powder suspension was proposed for the first time. The performance was evaluated by calculating the material removal rate for various combinations of pulse frequency and TiO<sub>2</sub> powder concentration. The obtained kerf of 54.16 ± 0.05 µm in depth demonstrated an increasing efficiency of more than 1.5 times with the closest analogs for the workpiece thickness up to 5 mm in height. The comparison of the performance (0.0083–0.0084 mm<sup>3</sup>/s) with the closest analogs shows that the results may correlate with the electrical properties of the assisting materials. |
| first_indexed | 2024-03-09T15:47:24Z |
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| id | doaj.art-1c36251084964a72aaeef2b41a12042d |
| institution | Directory Open Access Journal |
| issn | 2227-7080 |
| language | English |
| last_indexed | 2024-03-09T15:47:24Z |
| publishDate | 2022-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Technologies |
| spelling | doaj.art-1c36251084964a72aaeef2b41a12042d2023-11-24T18:23:00ZengMDPI AGTechnologies2227-70802022-11-0110611610.3390/technologies10060116Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water MediumSergey N. Grigoriev0Anna A. Okunkova1Marina A. Volosova2Khaled Hamdy3Alexander S. Metel4Department of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Moscow 127055, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Moscow 127055, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Moscow 127055, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Moscow 127055, RussiaDepartment of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Moscow 127055, RussiaAluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces contact loads and wear of cutting tools. However, most of the published works are related to the electrical discharge machining of alumina in hydrocarbons, which creates risks for the personnel and equipment due to the formation of chemically unstable dielectric carbides (methanide Al<sub>3</sub>C<sub>4</sub> and acetylenide Al<sub>2</sub>(C<sub>2</sub>)<sub>3</sub>). An alternative approach for wire electrical discharge machining Al<sub>2</sub>O<sub>3</sub> in the water-based dielectric medium using copper tape of 40 µm thickness and TiO<sub>2</sub> powder suspension was proposed for the first time. The performance was evaluated by calculating the material removal rate for various combinations of pulse frequency and TiO<sub>2</sub> powder concentration. The obtained kerf of 54.16 ± 0.05 µm in depth demonstrated an increasing efficiency of more than 1.5 times with the closest analogs for the workpiece thickness up to 5 mm in height. The comparison of the performance (0.0083–0.0084 mm<sup>3</sup>/s) with the closest analogs shows that the results may correlate with the electrical properties of the assisting materials.https://www.mdpi.com/2227-7080/10/6/116aluminaassisting coatingbrass wirecutting ceramicelectrical discharge machiningelectrode |
| spellingShingle | Sergey N. Grigoriev Anna A. Okunkova Marina A. Volosova Khaled Hamdy Alexander S. Metel Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium Technologies alumina assisting coating brass wire cutting ceramic electrical discharge machining electrode |
| title | Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium |
| title_full | Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium |
| title_fullStr | Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium |
| title_full_unstemmed | Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium |
| title_short | Electrical Discharge Machining of Al<sub>2</sub>O<sub>3</sub> Using Copper Tape and TiO<sub>2</sub> Powder-Mixed Water Medium |
| title_sort | electrical discharge machining of al sub 2 sub o sub 3 sub using copper tape and tio sub 2 sub powder mixed water medium |
| topic | alumina assisting coating brass wire cutting ceramic electrical discharge machining electrode |
| url | https://www.mdpi.com/2227-7080/10/6/116 |
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