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Microsystem Technologies

, Volume 20, Issue 10–11, pp 1875–1880 | Cite as

Microstructuring of non-conductive silicon carbide by electrical discharge machining

  • Florian ZellerEmail author
  • Tim Hösel
  • Claas Müller
  • Holger Reinecke
Technical Paper

Abstract

The electrical discharge machining process is an established process for machining materials regardless of their mechanical properties. Thus this process is especially attractive for materials which are hard to machine with conventional machining methods. The only requirement a material has to fulfil is having a certain electrical conductivity. Ceramic materials, (e.g. zirconia, silicon nitride or silicon carbide) exhibit excellent mechanical properties but are mostly electrically non-conductive. This can be compensated by an applied, electrically conductive assisting electrode. With this modification, the electrical discharge machining of non-conductive ceramic material is enabled. In this study the micro electrical discharge machining of non-conductive sintered silicon carbide is investigated. The drilling process shows instabilities due to the excessive generation of carbon products. A stabilisation of the process up to the maximum depth of 420 μm is realized by two approaches: adapting process parameters and adapting the tool electrode geometry. An analysis of the amount of infeed used in a milling process shows that an infeed of 15 μm has the best material removal rate to tool wear rate ratio. A maximum material removal rate of 3.58 × 10−3 mm3/min is achieved. Detached microstructures with an aspect ratio of 30 are machined. A conducted surface analysis indicates that the present removal mechanism is thermally induced spalling. Furthermore no heat affected zone is present in the machined near-surface area.

Keywords

Tool Wear Material Removal Material Removal Rate Electrical Discharge Machine Tool Electrode 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.

Notes

Acknowledgments

We would like to thank the “Ministerium für Wissenschaft, Forschung und Kunst Baden Württemberg” for the financial support of the graduate school “Generierungsmechanismen von Mikrostrukturen” (GenMik).

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Copyright information

© Springer-Verlag Berlin Heidelberg 2013

Authors and Affiliations

  • Florian Zeller
    • 1
    Email author
  • Tim Hösel
    • 1
  • Claas Müller
    • 1
  • Holger Reinecke
    • 1
  1. 1.Laboratory for Process Technology, Department of Microsystems Engineering, IMTEKUniversity of FreiburgFreiburgGermany

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