Skip to main content
Log in

Modeling and analysis of the effects of machining parameters on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Electric discharge machining (EDM) has achieved remarkable success in the manufacture of conductive ceramic materials for the modern metal industry. Mathematical models are proposed for the modeling and analysis of the effects of machining parameters on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic which are developed using the response surface methodology (RSM) to explain the influences of four machining parameters (the discharge current, pulse on time, duty factor and open discharge voltage) on the performance characteristics of the material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR). The experiment plan adopts the centered central composite design (CCD). The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). This study highlights the development of mathematical models for investigating the influences of machining parameters on performance characteristics and the proposed mathematical models in this study have proven to fit and predict values of performance characteristics close to those readings recorded experimentally with a 95% confidence interval. Results show that the main two significant factors on the value of the material removal rate (MRR) are the discharge current and the duty factor. The discharge current and the pulse on time also have statistical significance on both the value of the electrode wear ratio (EWR) and the surface roughness (SR).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. Schwartz MM (1995) Engineering applications of ceramic materials. Am Soc Metals, Metals Park, Ohio

    Google Scholar 

  2. Klocke F (1997) Modern approaches for the production of ceramic components. J Eur Ceram Soc 17:457–465

    Article  Google Scholar 

  3. Allor RL, Jahanmir S (1996) Current problems and future directions for ceramic machining. Am Soc Bull 75(7):40–43

    Google Scholar 

  4. McGeough JA (1988) Advanced methods of machining. Chapman & Hall, New York

    Google Scholar 

  5. Ajmal AJ (1981) The electrical discharge machining of silicon carbide. MSc Thesis, UMIST, UK

  6. Martin C, Cales B, Vivier P, Mathieu P (1989) Electrical discharge machinable ceramic composites. Mater Sci Eng A 109:352–356

    Google Scholar 

  7. Lee TC, Lau WS (1991) Materials manufacturing processes. Chapman & Hall, New York, pp 635–648

    Google Scholar 

  8. Matsuo T, Oshima E (1992) Investigation on the optimum carbide content and machining condition for wire EDM of zirconia ceramics. Ann CIRP 41(1):231–234

    Article  Google Scholar 

  9. Zhang JH, Lee TC, Lau WS (1997) Study on the electro-discharge machining of a hot pressed aluminum oxide based ceramic. J Mater Process Technol 63:908–912

    Article  Google Scholar 

  10. Sanchez JA, Cabanes I, Lopez de Lacalle LN, Lamikiz A (2001) Development of optimum electrodischarge machining technology for advanced ceramics. Int J Adv Manuf Technol 18:897–905

    Article  Google Scholar 

  11. Lauwers B, Kruth JP, Liu W, Eeraerts W, Schacht B, Bleys P (2004) Investigation of material removal mechanisms in EDM of composite ceramic materials. J Mater Process Technol 149:347–352

    Article  Google Scholar 

  12. Luis CJ, Puertas I, Villa G (2005) Material removal rate and electrode wear study on the EDM of silicon carbide. J Mater Process Technol 164–165:889–896

    Article  Google Scholar 

  13. Myers RH, Montgomery DH (1995) Response surface methodology. Wiley, New York

    MATH  Google Scholar 

  14. Grum J, Slab JM (2004) The use of factorial design and response surface methodology for fast determination of optimal heat treatment conditions of different Ni-Co-Mo surface layers. J Mater Process Technol 155–156:2026–2032

    Article  Google Scholar 

  15. Ozcelik B, Erzurmlu T (2005) Determination of effecting dimensional parameters on warpage of thin shell plastic parts using integrated response surface method and genetic algorithm. Int Commun Heat Mass Transf 32:1085–1094

    Article  Google Scholar 

  16. Kansal HK, Singh S, Kumar P (2005) Parametric optimization of powder mixed electrical discharge machining by response surface methodology. J Mater Process Technol 169:427–436

    Article  Google Scholar 

  17. Oktem H, Erzurmlu T, Kurtaran H (2005) Application of response surface methodology in the optimization of cutting conditions for surface roughness. J Mater Process Technol 170:11–16

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Ko-Ta Chiang.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Chiang, KT. Modeling and analysis of the effects of machining parameters on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic. Int J Adv Manuf Technol 37, 523–533 (2008). https://doi.org/10.1007/s00170-007-1002-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-007-1002-3

Keywords

Navigation