Journal of Materials Processing Technology 164–165 (2005) 889–896<br />
<br />
Material removal rate and electrode wear study on<br />
the EDM of silicon carbide<br />
C.J. Luis, I. Puertas ∗ , G. Villa<br />
Mechanical, Energetics and Materials Engineering Department, Manufacturing Engineering Section, Public University of Navarre,<br />
Campus de Arrosadia, Pamplona, Navarre 31006, Spain<br />
<br />
Abstract<br />
In this work, a material removal rate (MRR) and electrode wear (EW) study on the die-sinking electrical discharge machining (EDM) of<br />
siliconised or reaction-bonded silicon carbide (SiSiC) has been carried out. The selection of the above-mentioned conductive ceramic was<br />
made taking into account its wide range of applications in the industrial field: high-temperature gas turbines, bearings, seals and lining of<br />
industrial furnaces. This study was made only for the finish stages and has been carried out on the influence of five design factors: intensity<br />
supplied by the generator of the EDM machine (I), pulse time (ti ), duty cycle (η), open-circuit voltage (U) and dielectric flushing pressure<br />
(P), over the two previously mentioned response variables. This has been done by means of the technique of design of experiments (DOE),<br />
which allows us to carry out the above-mentioned analysis performing a relatively small number of experiments. In this case, a 25−1 fractional<br />
factorial design, whose resolution is V, has been selected considering the number of factors considered in the present study. The resolution<br />
of this fractional design allows us to estimate all the main effects, two-factor interactions and pure quadratic effects of the five design factors<br />
selected to perform this study.<br />
© 2005 Elsevier B.V. All rights reserved.<br />
Keywords: EDM; Manufacturing; Wear; DOE<br />
<br />
1. Introduction<br />
Electrical discharge machining (EDM) is a non-traditional<br />
manufacturing process based on removing material from a<br />
part by means of a series of repeated electrical discharges<br />
between a tool, called the electrode, and the part being machined in the presence of a dielectric fluid. At present, EDM<br />
is a widespread technique used in industry for high-precision<br />
machining of all types of conductive materials such as: metals, metallic alloys, graphite, or even some ceramic materials,<br />
of any hardness [1].<br />
The term, technical ceramic materials or advanced ceramic materials, is a relatively new term, which is applied to a<br />
range of various materials generally obtained from inorganic<br />
primary materials with a high grade of purity. These primary<br />
materials are subjected to typical processes in powder metallurgy technology and subsequently, to high-temperature sintering processes. With these materials, it is possible to obtain<br />
∗<br />
<br />
Corresponding author. Tel.: +34 948 169 305; fax: +34 948 169 099.<br />
E-mail address: inaki.puerta@unavarra.es (I. Puertas).<br />
<br />
0924-0136/$ – see front matter © 2005 Elsevier B.V. All rights reserved.<br />
doi:10.1016/j.jmatprotec.2005.02.045<br />
<br />
high-density parts which have excellent technical properties<br />
related to hardness, mechanical resistance, wear, and corrosion [2].<br />
In spite of their exceptional mechanical and chemical<br />
properties, ceramic materials have only achieved a partial<br />
acceptance in the field of industrial applications due to the<br />
difficulties in processing and the high costs associated with<br />
their manufacture. Over the past few years, the advances in<br />
the field of EDM have permitted the application of this technology to the manufacture of conductive ceramic materials.<br />
In line with current knowledge, the main inconvenience when<br />
applying the EDM technology to the field of ceramic materials is the electrical resistivity of these materials, where the<br />
limits are fixed between 100 and 300 cm [2–4].<br />
In this work, the selected ceramic material has been siliconised or reaction-bonded silicon carbide (SiSiC), whose<br />
field of applications is in constant growth. In this way, a material removal rate (MRR) and electrode wear (EW) study<br />
has been carried out on the influence of the following design factors: intensity (I), pulse time (ti ), duty cycle (η),<br />
open-circuit voltage (U) and dielectric flushing pressure (P).<br />
<br />
890<br />
<br />
C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br />
<br />
This has been performed using the techniques of design<br />
of experiments (DOE) and multiple linear regression analysis. In this case, a 25−1 fractional factorial design with<br />
resolution V has been employed to carry out the present<br />
study.<br />
<br />
2. Equipment used and conductive ceramic EDMed<br />
In this section, a brief description of the EDM machine<br />
used to perform the experiments and the conductive ceramic<br />
material studied in this work will be given.<br />
2.1. Die-sinking EDM machine<br />
The equipment used to perform the experiments was a<br />
die-sinking EDM machine of type ONA DATIC D-2030-S<br />
(Fig. 1). Also, a jet flushing system in order to assure the<br />
adequate flushing of the EDM process debris from the gap<br />
zone was employed. The dielectric fluid used for the EDM<br />
machine was a mineral oil (Oel-Held Dielektrikum IME 82)<br />
with a flash point of 82 ◦ C. The electrodes used were made of<br />
electrolytic copper (with a cross-section of 12 mm × 8 mm)<br />
and the polarity was negative.<br />
2.2. Reaction-bonded or siliconised silicon carbide<br />
F®<br />
<br />
silicon carThe ceramic material used was REFEL<br />
bide. This reaction-bonded silicon carbide (SiSiC) is manufactured by infiltrating silicon into a porous block made of<br />
silicon carbide powder and carbon, which is then submitted<br />
to a firing process at a specific temperature. This produces<br />
<br />
Fig. 1. EDM machine used to carry out the experiments.<br />
<br />
approximately 10% of free silicon, which fills the pores. The<br />
resulting microstructure has a low level of porosity and a<br />
very fine grain, giving a density of 3.1 g/cm3 . The mechanical resistance of the material (2000–3500 MPa to compression and 310 MPa to tension, up to 1350 ◦ C), combined with<br />
a hardness (25–35 GPa, Vickers hardness) which is higher<br />
than that of tungsten carbide (WC), explains its use as an<br />
element in high-temperature gas turbines as well as bearings<br />
and seals. Furthermore, it has a high thermal conductivity<br />
(150–200 W m−1 K−1 , 20 ◦ C) and a low thermal expansion<br />
coefficient (4.3–4.6 × 10−6 K−1 , 20–1000 ◦ C), which provides it with a good resistance to thermal shock. Reactionbonded silicon carbide performs better under chemical corrosion than other ceramic materials, such as tungsten carbide or<br />
alumina (Al2 O3 ). Therefore, it is frequently used as industrial<br />
furnaces lining.<br />
The samples of silicon carbide used in the experiments were ground sheets of the following dimensions:<br />
50 mm × 50 mm × 5 mm. Moreover, as was mentioned earlier, the electrodes used in this case were made of electrolytic<br />
copper and subjected to a negative polarity as, according to<br />
the bibliography in the EDM field and these authors’ experience [2,5], it is the most stable and recommended way to<br />
carry out the EDM process of silicon carbide.<br />
<br />
3. Design of the experiments<br />
In the present section, the design factors and response variables selected for this work, as well as the methodology employed for the experimentation, will be described.<br />
3.1. Design factors selected<br />
There are a large number of factors to consider within<br />
the EDM process, but in this work the level of the generator intensity (I), pulse time (ti ), duty cycle (η), open-circuit<br />
voltage (U) and dielectric flushing pressure (P) have only<br />
been taken into account as design factors. The reason why<br />
these five factors have been selected as design factors is that<br />
they are the most widespread and used amongst EDM researchers.<br />
The intensity (I) depends on the different power levels that<br />
can be supplied by the EDM machine generator. It represents<br />
the maximum value of the discharge current intensity. The<br />
intensity values used in the EDM machine programming are<br />
power levels of the generator, these corresponding with values of the peak intensity (Ip ), which is applied between the<br />
electrode and the part to be EDMed.<br />
Pulse time or on-time (ti ) is the duration of time (in s) the<br />
current is allowed to flow per cycle. On the other hand, duty<br />
cycle (η) is the percentage of pulse time relative to the total<br />
cycle time. This third factor is calculated by dividing pulse<br />
time by the total cycle time (i.e., pulse time plus pause time),<br />
where pause time or off-time (to ) is the duration of time (in<br />
s) between two consecutive sparks.<br />
<br />
C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br />
<br />
Open-circuit voltage (U) is the value of the electric tension<br />
applied between the part to be machined and the electrode just<br />
before the discharge is produced. Finally, the dielectric flushing pressure (P) is the pressure of the dielectric jet removing<br />
the EDM splinter or debris from the gap zone. This pressure<br />
value is measured by a pressure gauge in the EDM machine.<br />
3.2. Response variables selected<br />
The response variables selected for this study refer to the<br />
speed of the EDM process, i.e., material removal rate (MRR),<br />
and the efficiency of the copper electrode used, i.e., volumetric electrode wear (EW). These response variables are defined<br />
in Eqs. (1) and (2), respectively:<br />
MRR =<br />
EW =<br />
<br />
volume of material removed from part<br />
time of machining<br />
<br />
volume of material removed from electrode<br />
volume of material removed from part<br />
<br />
(1)<br />
(2)<br />
<br />
Although there are some other ways of measuring MRR and<br />
EW [6], in this work we have calculated them by the weight<br />
difference of the sample and the electrode just before and<br />
after being subjected to the EDM process. Moreover, density<br />
values of 3.10 and 8.96 g/cm3 were chosen for silicon carbide<br />
and electrolytic copper, respectively, in order to assess MRR<br />
and EW.<br />
3.3. Fractional factorial design employed<br />
The design of experiments (DOE) technique is a powerful work tool which allows us to model and analyse the<br />
influence of determined process variables over other specified variables, which are usually known as response variables.<br />
These response variables are unknown functions of the former design variables, which are also known as design factors<br />
[7–9].<br />
Within the design of experiments, there are various types<br />
that can be considered. One of the most widely known ones<br />
is the factorial design; this consists in experimenting with all<br />
the possible combinations of variables and levels. Nevertheless, if the number of design factors is reasonably high, as<br />
in this case, and it is possible to assume that certain highorder interactions are negligible, the information on the main<br />
effects and the low-order interactions may be obtained by<br />
running only a fraction of the complete factorial experiment.<br />
These fractional factorial designs are among the most widely<br />
used types of designs for product and process design and for<br />
process improvement [7].<br />
The design finally chosen was a 25−1 fractional factorial<br />
one with four central points. This design has a resolution of V,<br />
which means that no main effect or two-factor interaction in<br />
this model is aliased with any other main effect or two-factor<br />
interaction. The addition of four central points allows us to<br />
carry out lack-of-fit tests for the first-order models proposed,<br />
where a total of 20 experiments for these first-order designs<br />
<br />
891<br />
<br />
Table 1<br />
Levels selected for the five design factors of the 25−1 design<br />
Factors<br />
<br />
Levels<br />
−1<br />
<br />
I<br />
ti (s)<br />
η<br />
U (V)<br />
P (kPa)<br />
<br />
0<br />
<br />
+1<br />
<br />
3<br />
30<br />
0.4<br />
−120<br />
20<br />
<br />
4<br />
50<br />
0.5<br />
−160<br />
40<br />
<br />
5<br />
70<br />
0.6<br />
−200<br />
60<br />
<br />
were made. In case the first-order model turned out not to be<br />
adequate for modelling the behaviour of the response variable<br />
to be studied, this was widened by adding 10 star points, thus<br />
giving a central composite design with the star points located<br />
in the centres of the faces. Thus, the case of the secondorder model consisted of a total of 30 experiments, i.e., the<br />
previous 20 of the first-order model plus the new 10 of the star<br />
points.<br />
The low and high levels selected for intensity, pulse time,<br />
duty cycle, open-circuit voltage and dielectric flushing pressure were: 3 and 5, 30 and 70 s, 0.4 and 0.6, −120 and<br />
−200 V and finally, 20 and 60 kPa, respectively. The levels of the intensity factor (3 and 5) are equivalent to 2 and<br />
6 A, respectively. A summary of the levels selected for the<br />
factors to be studied is shown in Table 1. The previous selection of variation levels was made taking into account that<br />
the authors wanted this study to be focused on the area of<br />
the finish machining stages, owing to the influence that a<br />
good surface quality has on such important properties, in the<br />
case of ceramic materials, such as fatigue and wear resistance<br />
[8,9].<br />
Table 2 shows the design matrix for the second-order models as well as the values obtained in the experiments for the<br />
response variables studied in this work, i.e., MRR and EW.<br />
As can be observed in this table, rows 1–16 correspond to the<br />
fractional factorial design, rows 17–26 correspond to the star<br />
points and finally, the central points are placed in the four<br />
last rows of the design matrix. On the other hand, the design<br />
matrix for the first-order model of MRR and EW would be<br />
obtained simply by eliminating the 10 rows corresponding to<br />
the star points.<br />
The graphs, models and tables that are to be presented<br />
in the following two sections were produced using the DOE<br />
module of the software STATGRAPHICS® plus v. 5.0.<br />
<br />
4. Results and analysis of MRR<br />
A first-order model was proposed for the response variable MRR, where this was rejected as a result of the values<br />
obtained for the curvature test that can be seen in Table 3.<br />
As in this case the P-value, which is equal to 0.0002, is<br />
lower than 0.05, the null hypothesis that there are no pure<br />
quadratic effects in the model is therefore rejected, accepting<br />
<br />
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C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br />
<br />
Table 2<br />
Design matrix for the second-order models of MRR and EW<br />
I<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
21<br />
22<br />
23<br />
24<br />
25<br />
26<br />
27<br />
28<br />
29<br />
30<br />
<br />
ti (s)<br />
<br />
η<br />
<br />
U (V)<br />
<br />
P (kPa)<br />
<br />
EW (%)<br />
<br />
MRR (mm3 /min)<br />
<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
3<br />
5<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
4<br />
<br />
30<br />
30<br />
70<br />
70<br />
30<br />
30<br />
70<br />
70<br />
30<br />
30<br />
70<br />
70<br />
30<br />
30<br />
70<br />
70<br />
50<br />
50<br />
30<br />
70<br />
50<br />
50<br />
50<br />
50<br />
50<br />
50<br />
50<br />
50<br />
50<br />
50<br />
<br />
0.4<br />
0.4<br />
0.4<br />
0.4<br />
0.6<br />
0.6<br />
0.6<br />
0.6<br />
0.4<br />
0.4<br />
0.4<br />
0.4<br />
0.6<br />
0.6<br />
0.6<br />
0.6<br />
0.5<br />
0.5<br />
0.5<br />
0.5<br />
0.4<br />
0.6<br />
0.5<br />
0.5<br />
0.5<br />
0.5<br />
0.5<br />
0.5<br />
0.5<br />
0.5<br />
<br />
−120<br />
−120<br />
−120<br />
−120<br />
−120<br />
−120<br />
−120<br />
−120<br />
−200<br />
−200<br />
−200<br />
−200<br />
−200<br />
−200<br />
−200<br />
−200<br />
−160<br />
−160<br />
−160<br />
−160<br />
−160<br />
−160<br />
−120<br />
−200<br />
−160<br />
−160<br />
−160<br />
−160<br />
−160<br />
−160<br />
<br />
60<br />
20<br />
20<br />
60<br />
20<br />
60<br />
60<br />
20<br />
20<br />
60<br />
60<br />
20<br />
60<br />
20<br />
20<br />
60<br />
40<br />
40<br />
40<br />
40<br />
40<br />
40<br />
40<br />
40<br />
20<br />
60<br />
40<br />
40<br />
40<br />
40<br />
<br />
10.29<br />
7.34<br />
19.82<br />
10.01<br />
11.87<br />
9.83<br />
13.55<br />
12.16<br />
12.66<br />
7.48<br />
16.06<br />
7.91<br />
12.84<br />
11.63<br />
16.33<br />
9.29<br />
13.29<br />
7.47<br />
6.61<br />
6.74<br />
6.92<br />
10.50<br />
10.92<br />
8.00<br />
7.24<br />
6.65<br />
6.61<br />
7.06<br />
7.25<br />
7.51<br />
<br />
0.033<br />
0.104<br />
0.020<br />
0.116<br />
0.049<br />
0.091<br />
0.030<br />
0.136<br />
0.051<br />
0.312<br />
0.030<br />
0.267<br />
0.092<br />
0.344<br />
0.055<br />
0.354<br />
0.032<br />
0.283<br />
0.244<br />
0.177<br />
0.147<br />
0.168<br />
0.087<br />
0.258<br />
0.195<br />
0.201<br />
0.189<br />
0.199<br />
0.199<br />
0.201<br />
<br />
that there is statistical evidence of curvature in the first-order<br />
model, for a confidence level of 95%. Thus, that the proposed first-order model is suitable for a significance level<br />
α of 0.05 is rejected and so, the second-order model is<br />
selected.<br />
Table 4 shows the ANOVA table for the case of the<br />
second-order model proposed, where now, the total number of degrees of freedom is equal to 29. As can be observed in this table, there are three effects with a P-value<br />
less than 0.05, which means that they are significant for<br />
a confidence level of 95%. These significant effects, arranged in order of importance, are: the main effects of intensity and voltage and finally, the interaction effect between<br />
them.<br />
On the other hand, a value of 0.9794 was obtained for the<br />
R2 -statistic, which signifies that the model explains 97.94%<br />
of the variability of MRR, whereas the adjusted R2 -statistic<br />
(R2 ) is 0.9335.<br />
adj<br />
<br />
The equation of the second-order proposed model is that<br />
shown in Eq. (3):<br />
MRR = −0.985466 + 0.151912 · I − 0.00642768 · ti<br />
+3.08858 · η − 0.000251344 · U−0.00216784 · P<br />
−0.0344143 · I 2 + 0.00035 · I · ti +0.02125 · I · η<br />
+0.00114688 · I · U + 0.0000375 · I · P<br />
+0.0000464643 · ti2 + 0.0020625 · ti · η<br />
−0.00000921875 · ti · U + 0.00001125 · ti · P<br />
−3.44143 · η2 + 0.002375 · η · U<br />
−0.0020625 · η · P − 0.0000121339 · U 2<br />
+0.00000859375 · U · P + 0.0000152143 · P 2<br />
(3)<br />
<br />
Table 3<br />
Analysis of variance table for the curvature test of the first-order model of MRR<br />
Source of variation<br />
<br />
Sum of squares<br />
<br />
Degrees of freedom<br />
<br />
Mean square<br />
<br />
F-ratio<br />
<br />
P-value<br />
<br />
Curvature<br />
Pure error<br />
Total error<br />
<br />
0.014258<br />
0.000088<br />
0.014346<br />
<br />
1<br />
3<br />
4<br />
<br />
0.014258<br />
0.000029<br />
<br />
486.06<br />
<br />
0.0002<br />
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C.J. Luis et al. / Journal of Materials Processing Technology 164–165 (2005) 889–896<br />
<br />
893<br />
<br />
Table 4<br />
Analysis of variance table for the second-order model of MRR<br />
Source of variation<br />
<br />
Sum of squares<br />
<br />
Degrees of freedom<br />
<br />
Mean square<br />
<br />
F-ratio<br />
<br />
P-value<br />
<br />
A:I<br />
B:ti<br />
C:η<br />
D:U<br />
E:P<br />
AA<br />
AB<br />
AC<br />
AD<br />
AE<br />
BB<br />
BC<br />
BD<br />
BE<br />
CC<br />
CD<br />
CE<br />
DD<br />
DE<br />
EE<br />
Total error<br />
Total<br />
<br />
0.144901<br />
0.001013<br />
0.003173<br />
0.066856<br />
0.000080<br />
0.002909<br />
0.000784<br />
0.000072<br />
0.033672<br />
0.000009<br />
0.000848<br />
0.000272<br />
0.000870<br />
0.000324<br />
0.002909<br />
0.001444<br />
0.000272<br />
0.000926<br />
0.000756<br />
0.000091<br />
0.005940<br />
0.287711<br />
<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
1<br />
9<br />
29<br />
<br />
0.144901<br />
0.001013<br />
0.003173<br />
0.066856<br />
0.000080<br />
0.002909<br />
0.000784<br />
0.000072<br />
0.033672<br />
0.000009<br />
0.000848<br />
0.000272<br />
0.000870<br />
0.000324<br />
0.002909<br />
0.001444<br />
0.000272<br />
0.000926<br />
0.000756<br />
0.000091<br />
0.000660<br />
<br />
219.53<br />
1.53<br />
4.81<br />
101.29<br />
0.12<br />
4.41<br />
1.19<br />
0.11<br />
51.02<br />
0.01<br />
1.29<br />
0.41<br />
1.32<br />
0.49<br />
4.41<br />
2.19<br />
0.41<br />
1.40<br />
1.15<br />
0.14<br />
<br />
0.0000<br />
0.2468<br />
0.0560<br />
0.0000<br />
0.7354<br />
0.0652<br />
0.3041<br />
0.7483<br />
0.0001<br />
0.9096<br />
0.2862<br />
0.5367<br />
0.2805<br />
0.5012<br />
0.0652<br />
0.1732<br />
0.5367<br />
0.2666<br />
0.3123<br />
0.7190<br />
<br />
where the variable values have been specified according to<br />
their original units. The ANOVA table shown in Table 4 can<br />
be used in order to simplify the models, especially for the<br />
case of polynomial ones. In this way, the simplified model<br />
which presents the highest value for the adjusted R2 -statistic<br />
is that shown in Eq. (4):<br />
MRR = −0.99879 + 0.152933 · I − 0.00529342 · ti<br />
+3.05541 · η − 0.000528938 · U − 0.001375 · P<br />
−0.0330263 · I 2 + 0.00035 · I · ti<br />
+0.00114687 · I · U + 0.0000499342 · ti2<br />
−0.00000921875 · ti · U − 3.30263 · η2<br />
<br />
Fig. 2. Main effects plot for MRR.<br />
<br />
+0.002375 · η · U − 0.0000112664 · U 2<br />
<br />
giving the latter a better flushing of the EDM debris. With<br />
respect to duty cycle, although its influence is not significant,<br />
MRR tends to increase until a maximum peak (near its central<br />
value of 0.5) after which MRR decreases. If pause time (to )<br />
<br />
+0.00000859375 · U · P<br />
<br />
(4)<br />
<br />
where now, the adequacy statistics are 0.9755 (R2 ) and 0.9555<br />
(R2 ). Nevertheless, the first model (with no simplifications)<br />
adj<br />
is to be considered in this study on MRR in order to take into<br />
account the contribution of all the possible effects.<br />
Figs. 2 and 3 show the main effects plot and interaction<br />
plot for material removal rate, respectively. As can be observed in Fig. 2, the most influential factors are intensity and<br />
open-circuit voltage, where the three remaining factors for<br />
a 95% confidence level have no influence on MRR. Moreover, material removal rate greatly increases when these two<br />
factors are increased, where these tendencies are the ones<br />
that one could expect a priori, as more energetic pulses usually lead to a higher material removal and on the other hand,<br />
an increase in the ionisation or breakdown voltage results in<br />
an increase in both the discharge energy and the work gap,<br />
<br />
Fig. 3. Interaction plot for MRR.<br />
<br />