Measuring the Influence of Process Parameter on CuCr Electrode Tool Wear Rate for Biocompatible Zr-Based BMG Cutting Using Sinking-EDM

Abstract:

Subsequent processing through machining for biocompatible Zr-based BMG previously developed is needed in order to enlarge the material application, especially for medical devices. In this study the performance of CuCr tool on EDM process was investigated to cut biocompatible Zr-based BMG having low machinability nature. The experiment utilized volume loss technique to measure the TWR and consecutive SEM observation to reveal the tool wear mechanism of selected tool samples. The tool wear behavior was strongly characterized by the combination of discharge current and pulse-on time, where the larger TWR obtained by higher current and shorter pulse-on time. By SEM analysis, the irregular-shaped surface morphology with the presence of debris was observed on the tool wear region resulted by high discharge energy process. Additionally, the larger crater size, microvoids and numerous debris particles were also appeared on BMG workpiece surface machined using higher discharge energy.

• Periodical: Key Engineering Materials (Volume 851)
• Pages: 68-75
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.851.68
• Online since: July 2020
• Authors: Yanuar Rohmat Aji Pradana*, Firhan Ahmad Fanani, Aminnudin Aminnudin, Wahono Wahono, Jason Shian-Ching Jang
• Keywords: Biocompatible Zr-Based BMG, CuCr Tool Wear, Electrical Discharge Machining

References

[1] J. C. Huang, J. P. Chu, and J. S. C. Jang, Recent progress in metallic glasses in Taiwan, Intermetallics, vol. 17, no. 12, (2009) p.973–987.

DOI: 10.1016/j.intermet.2009.05.004

[2] A. Inoue and A. Takeuchi, Recent development and application products of bulk glassy alloys, Acta Mater., vol. 59, no. 6, (2011) p.2243–2267.

DOI: 10.1016/j.actamat.2010.11.027

[3] T. Egami, Understanding the properties and structure of metallic glasses at the atomic level, JOM, vol. 62, no. 2, (2010) p.70–75.

DOI: 10.1007/s11837-010-0036-4

[4] A. Hirata et al., Direct observation of local atomic order in a metallic glass, Nat. Mater., vol. 10, p.28, Nov. (2010).

[5] A. Inoue and T. Zhang, Fabrication of Bulk Glassy Zr55Al10Ni5Cu30 Alloy of 30 mm in Diameter by a Suction Casting Method, Mater. Transitions, vol. 37, (1996) p.185–187.

DOI: 10.2320/matertrans1989.37.185

[6] X. Hui et al., High-zirconium-based bulk metallic glasses with large plasticity, Scr. Mater., vol. 63, no. 2, (2010) p.239–242.

[7] T. H. Li et al., Significantly enhanced mechanical properties of ZrAlCo bulk amorphous alloy by microalloying with Ta, Intermetallics, vol. 93, no. (2018) p.162–168.

DOI: 10.1016/j.intermet.2017.12.008

[8] N. K. Maroju, D. P. Yan, B. Xie, and X. Jin, Investigations on surface microstructure in high-speed milling of Zr-based bulk metallic glass, J. Manuf. Process., vol. 35, no. June, (2018) p.40–50.

DOI: 10.1016/j.jmapro.2018.07.020

[9] X. Chen, J. Xiao, Y. Zhu, R. Tian, X. Shu, and J. Xu, Micro-machinability of bulk metallic glass in ultra-precision cutting, Mater. Des., vol. 136, (2017) p.1–12.

DOI: 10.1016/j.matdes.2017.09.049

[10] M. Bakkal, Electron microscopy of bulk metallic glass machining chips, J. Non. Cryst. Solids, vol. 355, no. 45–47, (2009) p.2220–2223.

DOI: 10.1016/j.jnoncrysol.2009.07.018

[11] J. D. Patel and K. D. Maniya, A Review on : Wire cut electrical discharge machining process for metal matrix composite, Procedia Manuf., vol. 20, (2018) p.253–258.

DOI: 10.1016/j.promfg.2018.02.037

[12] C. Liu, N. Duong, M. P. Jahan, J. Ma, and R. Kirwin, Experimental investigation and numerical simulation of micro-EDM of bulk metallic glass with focus on crater sizes, Procedia Manuf., vol. 34, (2019) p.275–286.

DOI: 10.1016/j.promfg.2019.06.151

[13] H. G. Cheong, Y. S. Kim, and C. N. Chu, Effect of reverse current on tool wear in micro-electrical discharge milling, Precis. Eng., vol. 55 (2019) pp.484-490.

DOI: 10.1016/j.precisioneng.2018.11.003

[14] T. Muthuramalingam and B. Mohan, A review on influence of electrical process parameters in EDM process, Arch. Civ. Mech. Eng., vol. 15, 1 (2015) p.87–94.

DOI: 10.1016/j.acme.2014.02.009

[15] H. Huang and J. Yan, On the surface characteristics of a Zr-based bulk metallic glass processed by microelectrical discharge machining, Appl. Surf. Sci., vol. 355, (2015) p.1306–1315.

DOI: 10.1016/j.apsusc.2015.08.239

[16] S. H. Yeo, P. C. Tan, E. Aligiri, S. B. Tor, and N. H. Loh, Processing of Zirconium-Based Bulk Metallic Glass (BMG) Using Micro Electrical Discharge Machining (Micro-EDM), Mater. Manuf. Process., vol. 24, no. 12, (2009) p.1242–1248.

DOI: 10.1080/10426910903129661

[17] C. C. Wang and B. H. Yan, Blind-hole drilling of Al2O3 / 6061Al composite using rotary electro-discharge machining, J. Mater. Prosc. Technol. vol. 102, (2000) p.90–102.

DOI: 10.1016/s0924-0136(99)00423-9

[18] B. Mohan, A. Rajadurai, and K. G. Satyanarayana, Effect of SiC and rotation of electrode on electric discharge machining of Al - SiC composite, J. Mater. Prosc. Technol. vol. 124, (2002) pp.297-304.

DOI: 10.1016/s0924-0136(02)00202-9

[19] S. H. Yeo, P. C. Tan, E. Aligiri, S. B. Tor, and N. H. Loh, Processing of Zirconium-Based Bulk Metallic Glass (BMG) Using Micro Electrical Discharge Machining (Micro-EDM), Mater. Manuf. Process., vol. 24, no. 12, (2009) p.1242–1248.

DOI: 10.1080/10426910903129661

[20] A. Kumar and K. Æ. L. C. Pathak, Microanalysis of debris formed during electrical discharge machining ( EDM ), J. Mater. Sci., vol. 42, (2007) p.872–877.

DOI: 10.1007/s10853-006-0020-0

[21] U. Maradia, M. Boccadoro, J. Stirnimann, F. Kuster, and K. Wegener, Electrode wear protection mechanism in meso – micro-EDM, J. Mater. Process. Technol., vol. 223, (2015) p.22–33.

DOI: 10.1016/j.jmatprotec.2015.03.039

[22] J. Murray, D. Zdebski, and A. T. Clare, Workpiece debris deposition on tool electrodes and secondary discharge phenomena in micro-EDM, J. Mater. Process. Technol., vol. 212, no. 7, (2012) p.1537–1547.

DOI: 10.1016/j.jmatprotec.2012.02.019

[23] H. G. Cheong, Y. S. Kim, and C. N. Chu, Effect of reverse current on tool wear in micro-electrical discharge milling, Precis. Eng., vol. 55, (2019) p.484–490.

DOI: 10.1016/j.precisioneng.2018.11.003

[24] P. Taylor, T. Muthuramalingam, and B. Mohan, Influence of Discharge Current Pulse on Machinability in Electrical Discharge Machining, Materials and Manufacturing Processes no. October, (2013) p.37–41.

DOI: 10.1080/10426914.2012.746700

[25] H. Huang and J. Yan, Microstructural changes of Zr-based metallic glass during micro-electrical discharge machining and grinding by a sintered diamond tool, J. Alloys Compd., vol. 688, (2016) p.14–21.

DOI: 10.1016/j.jallcom.2016.07.181