Puertas 2004
Puertas 2004
Puertas 2004
Abstract
In this work, a comparative study of the electrical discharge machining (EDM) of three different conductive ceramics has been carried out.
The ceramics used in the experiments were cobalt-bonded tungsten carbide (WC–Co), hot-pressed boron carbide (B4 C) and reaction-bonded
silicon carbide (SiSiC). This study has been done only for the finishing stages and the selection of the above-mentioned conductive ceramics
was motivated by their wide range of applications: machining and mining for WC–Co, thermal-neutron absorber and nozzles for B4 C
and wear parts and heat exchangers for SiSiC, among others. The comparative study has been carried out on the influence of the design
factors of intensity (I), pulse time (ti ) and duty cycle (η) over response variables such as surface roughness (evaluated through the Ra
parameter), volumetric electrode wear (EW) and material removal rate (MRR). This was accomplished through the technique of design of
experiments (DOE), along with multiple linear regression techniques, which allowed us to carry out the analysis with only a small number
of experiments.
© 2004 Elsevier B.V. All rights reserved.
0924-0136/$ – see front matter © 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2004.04.197
1034 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038
microfine control, which allowed us to obtain a mirror-type 2.4. Ceramic material of tungsten carbide (WC–Co)
surface finish for the case of steels. This additional equip-
ment consists of a series of stages formed by capacitors, The third material used in the experiments was 94WC–6Co
which provide variable capacity between the part and the tungsten carbide. This material was principally developed
electrode. in order to be used as cutting tool, due to its excellent
hardness properties (HRA 92). Furthermore, it possesses
a high compressive strength (5450 MPa), as well as good
2.2. Ceramic material of boron carbide (B4 C)
resistance to wear and oxidation at high temperatures. On
the other hand, the compound material made up of tung-
The first ceramic material used in the experiments was
sten carbide and cobalt has a high resistance to thermal
hot-pressed boron carbide (B4 C). It has excellent properties
shock and, consequently, it is capable of coping with rapid
of hardness (37 GPa), resistance to wear as well as fracture
changes of temperature. In the case of 94WC–6Co, it has a
toughness (3–4 MPa m1/2 ). Its density is low (2.50 g/cm3 )
thermal conductivity of 100 W/m K and a thermal expansion
but, on the other hand, it has a high compressive strength
coefficient of 4.3 × 10−6 K−1 , at a temperature of 200 ◦ C.
(2855 MPa) and a high module of elasticity (445 GPa), which
At present, although approximately 50% of the manufac-
makes its use as ballistic material one of its widest applica-
turing of this type of cemented carbides is used in machin-
tions. As 20% of natural boron is made up of the isotope of
ing applications, the number of alternative applications is
boron B10 , it presents a high neutron capture cross-section
quickly growing, where the most important areas are mining,
and so is usually used in neutron absorption applications
construction, transport and drilling in oil and gas installa-
such as lining in nuclear fission reactors.
tions, metal forming, structural components and as material
The samples of boron carbide used in the experi-
for tools in the field of forestry engineering.
ments were ground sheets of the following dimensions:
The samples of tungsten carbide were ground sheets of
50 mm × 50 mm × 4 mm. Moreover, the electrodes used
dimensions: 50 mm × 50 mm × 4 mm. As in the two pre-
were made of electrolytic copper as it is the most highly
vious cases, the electrodes used were made of electrolytic
recommended material for the EDM process of boron car-
copper because, according to the bibliographic sources con-
bide [4,5]. The selected copper electrodes (with positive
sulted [7,8], it is the most highly recommended material for
polarity for B4 C) used in this study for all the ceramic ma-
the EDM of tungsten carbide. Furthermore, it is also rec-
terials were of a prismatic shape and with a cross section of
ommended that negative polarity for the electrode should
8 mm × 12 mm.
be used in order to ensure a much more stable machining
process.
2.3. Ceramic material of silicon carbide (SiSiC)
2.5. Design factors
The second ceramic material used in this work was
reaction-bonded or siliconised silicon carbide (REFEL F® ). There are a large number of factors to consider within
The mechanical resistance (2000–3500 MPa to compres- the EDM process, but in this work we have only considered
sion and 310 MPa to tension) combined with a hardness the generator intensity (I), pulse time (ti ) and duty cycle
(25–35 GPa, Vickers hardness) which is higher than that (η). The reason why these three factors have been selected
of tungsten carbide explains its use as an element in high as design factors is that they are the most widespread and
temperature gas turbines as well as forming part of bear- frequently-used ones among EDM researchers.
ings and seals. Furthermore, it has a high thermal con-
ductivity (150–200 W m−1 K−1 , at 20 ◦ C) and a thermal 2.6. Response technological variables
expansion coefficient (4.3–4.6 × 10−6 K−1 , for an interval
of 20–1000 ◦ C) which gives it good resistance to thermal The response variables studied in this work were surface
shock. Reaction-bonded silicon carbide performs better un- roughness, material removal rate and electrode wear. The
der chemical corrosion than other ceramic materials such previous variables were chosen because of their importance
as tungsten carbide or alumina (Al2 O3 ). It is therefore within the EDM research field.
frequently used as lining for industrial furnaces. The surface roughness parameter which was selected as
The samples of silicon carbide were ground sheets of a response variable was the arithmetic average roughness of
dimensions: 50 mm × 50 mm × 5 mm. As in the case of the roughness profile (Ra ). This surface roughness parame-
the earlier ceramic material, the electrodes used were made ter is defined in accordance with UNE-EN-ISO 4287: 1999.
of electrolytic copper, as, according to the bibliographic When carrying out the surface roughness measurements over
sources consulted [6,7], it is the most highly recommended the ceramic materials, a phase corrected 2CR filter was se-
material for the EDM of silicon carbide. Conversely, the lected for the rugosimeter, along with a length of measure-
use of negative polarity for the electrode is recommended ment of 6.4 mm (8 mm × 0.8 mm). Moreover, a stylus tip
for this material, as the machining process can therefore be radius of 3 m, a stylus speed of 1 mm/s and a stylus static
carried out in a more stable way. force of 0.12 mN were used.
I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038 1035
3. Design of the experiments Fig. 1 shows the intensity factor effect over the Ra param-
eter for the ceramic materials considered in this study.
The design which was finally chosen was a factorial de- As can be observed in Fig. 1, in both silicon carbide and
sign 23 with four central points, which provide protection tungsten carbide the Ra parameter tends to increase signif-
against curvature, and a total of 12 experiments were made icantly when intensity increases. Conversely, in the case of
[9,10]. Consequently, for the case of the response variables boron carbide Ra this tends to decrease with the increase in
which were not adequate for the previous first order model, intensity although, in this case, this factor does not turn out
this was widened by the addition of six star points, giving to be statistically significant for the considered confidence
then a central composite design made up of the star points level. In practice, this diminution tendency in the Ra param-
situated in the centres of the faces; that is to say, a total of eter with the intensity factor is exactly the opposite of what
18 experiments in the case of this second order model. would be expected a priori, as increases in pulse energy are
Table 1 presents the relationship between factors and their usually associated, by and large, with a worsening in the
selected variation levels, taking into consideration that the material surface roughness.
study wanted to focus on the case of finishing machining Fig. 2 shows the pulse time effect over the Ra parameter
stages. for the different ceramic materials under study.
Table 2 shows the design matrix resulting from the type of As can be seen in Fig. 2, the Ra parameter tends to in-
experiment selected in the case of the second order model, crease when pulse time is increased for all the considered
as well as the observations for the case of the three response materials. The most notable increase is produced for boron
variables which are considered in this study, where the in- carbide, the effect of this factor being rather less significant
tensity values 3, 4 and 5 are equivalent to 2A, 4A and 6A, in the case of silicon carbide. Furthermore, in this latter case
respectively. The design matrix for the first order model is the Ra parameter seems to tend to decrease somewhat for
obtained by merely eliminating the rows corresponding to
the star points of the model.
After having performed a series of curvature tests for each
of the ceramic materials and each of their corresponding
Table 1
Factors and levels selected for the experiments
Factors Levels
−1 +1
I 3 5
ti (s) 10 50
η 0.4 0.6 Fig. 2. Comparison of the ti factor effect over Ra for the different ceramic
materials.
1036 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038
Table 2
Design of experiment matrix obtained for the case of the second order model
Number I ti (s) η B4 C SiSiC WC–Co
pulse time values close to its highest level of 50 s. There- remains constant, surface finish tends to worsen because the
fore, the tendency of Ra with regard to this design factor stability of the process is affected.
is exactly what would be expected a priori, as decreasing
the frequency of the pulse usually leads to worse values of 4.2. Comparative analysis of the electrode wear EW
surface roughness.
Fig. 3 shows a comparative graph of the duty cycle effect Fig. 4 shows the main effect of the intensity factor over
over the Ra parameter for the three ceramic materials studied the response variable of EW, for the different materials con-
in this work. As can be observed in this figure, in the cases sidered in this study. In the case of boron carbide, the elec-
of silicon carbide and tungsten carbide, the Ra parameter trode wear tends to increase when intensity increases. On
increases when duty cycle is increased, especially for silicon the contrary, in the cases of silicon carbide and tungsten car-
carbide, while this effect is not statistically significant for bide, the wear value decreases significantly, with intensity
tungsten carbide, within the considered confidence level. down to a minimum value after which the electrode wear
In the case of boron carbide, the Ra parameter tends to de- increases with the increase in the previous factor. In prac-
crease lightly when duty cycle is increased, although, in this tice, the logical tendency to expect, a priori, would be of a
case, the effect of this factor is not statistically significant decrease in the electrode wear as we move towards stages
for the confidence level under consideration in this study. On with greater pulse energy, that is, growing intensity levels.
the other hand, this tendency of the Ra parameter to decrease Fig. 5 shows the effect of the pulse time factor over the
when duty cycle increases, within the considered work in- EW variable for the different ceramic materials. As can be
terval, is exactly the opposite of what would be expected in seen in Fig. 5, in the case of boron carbide, the electrode
practice, as, when pause time tends to decrease, which is wear value tends to decrease greatly with an increase in pulse
equivalent to increasing the duty cycle factor if pulse time time, which coincides with the behaviour which would be
Fig. 3. Comparison of the η factor effect over Ra for the different ceramic Fig. 4. Comparison of the I factor effect over EW for the different ceramic
materials. materials.
I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038 1037
Fig. 5. Comparison of the ti factor effect over EW for the different Fig. 7. Comparison of the I factor effect over MRR for the different
ceramic materials. ceramic materials.
Fig. 6. Comparison of the η factor effect over EW for the different ceramic Fig. 8. Comparison of the ti factor effect over MRR for the different
materials. ceramic materials.
1038 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038
sten carbide, it has been observed that the wear value de-
creases with the increase in intensity until reaching a min-
imum value. Furthermore, the electrode wear tends to de-
crease with the increase in pulse time in the case of boron
carbide. On the other hand, in the cases of silicon carbide
and tungsten carbide, just the opposite behaviour was ob-
served. Finally, it has been observed that EW tends to in-
crease when duty cycle is increased in the cases of boron
carbide and silicon carbide, whilst in the case of tungsten
carbide, it increases up to a maximum value after which it
Fig. 9. Comparison of the η factor effect over MRR for the different
ceramic materials.
decreases.
With regard to material removal rate, it has been con-
firmed that in all cases this increases when intensity in-
Fig. 9 shows a comparative graph of the effect of duty
creases, although, in the case of boron carbide, this tendency
cycle over MRR for the three ceramic materials studied.
to grow reaches a maximum value after which it starts to
As shown in Fig. 9, the value of material removal rate
decrease. Furthermore, the fact of increasing pulse time
tends, in all the ceramic materials which were studied, to
produces a decrease in material removal rate, in the cases
increase when duty cycle has also been increased. This co-
of silicon carbide and tungsten carbide. In the case of boron
incides with what would be expected in practice, based on
carbide, it decreases with pulse time down to a minimum
the experience acquired in the field of EDM for other ma-
value, after which it tends to increase. On the other hand,
terials, as, when pause time is reduced, which is equivalent
it has been observed that material removal rate tends to
to increasing duty cycle, the MRR value tends to increase.
increase when duty cycle is increased for all the cases.
Furthermore, as can be seen in the previous Fig. 9, this ten-
dency for material removal rate to increase with duty cycle
is much more pronounced in the case of boron carbide than References
in the case of the other two remaining ceramic materials.
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