Micro Electro Discharge Machining of Non-Conductive Ceramic


Article Preview

Electro discharge machining (EDM) as a die sinking process has taken off in 1943. Since then it was known as a non-conventional machining process and its application was limited for processing only electrically conductive materials. Later on, due to the widespread applications, this EDM process is considered conventional as usual. However, in the recent years EDM has gone through considerable changes especially with dielectric fluids, simple to complex geometry, meso to micro sized structures, nanometric surface finish, and so on. In addition, the application of EDM has also been extended for processing electrically semi-conductive and non-conductive materials like ceramics and composites. This paper discussed micro electro discharge machining of non-conductive ceramic materials. It includes detail process development, modelling of material removal rate and surface finish which include the effect of multi spark and random spalling conditions.



Edited by:

Sujan Debnath




M. Y. Ali et al., "Micro Electro Discharge Machining of Non-Conductive Ceramic", Materials Science Forum, Vol. 911, pp. 20-27, 2018

Online since:

January 2018




* - Corresponding Author

[1] Y.F. Chen, Y.C. Lin, S.L. Chen, and L.R. Hsu: Optimization of electrodischarge machining parameters on ZrO2 ceramic using the Taguchi method. Journal of Engineering Manufacture, 224, (2009), pp.195-205.

DOI: https://doi.org/10.1243/09544054jem1437

[2] A. Schubert, H. Zeidler, M. Hackert, J. Schneider and M. Hahn: Enhancing micro-EDM using ultrasonic vibration and approaches for machining of nonconducting ceramics. Journal of Mechanical Engneering, 59 (3) (2013), pp.156-164.

DOI: https://doi.org/10.5545/sv-jme.2012.442

[3] D.K. Chung, H.S. Shin, M.S. Park and C.N. Chu: Machining characteristics of micro EDM in water using high frequency bipolar pulse. International Journal of Precision Engineering and Manufacturing, 12 (2) (2011), pp.195-201.

DOI: https://doi.org/10.1007/s12541-011-0027-6

[4] A. Schubert, H. Ziedler, N. Wolf and M. Hackert: Micro electro discharge machining of electrically nonconductive ceramics. AIP Conference Proceedings, 1353 (1) (2011), pp.1303-1308.

DOI: https://doi.org/10.1063/1.3589696

[5] Y. Wong, M. Rahman, H. Lim, H. Han and N. Ravi: Investigation of micro-EDM material removal characteristics using single RC-pulse discharges. Journal of Materials Processing Technology, 140 (1) (2003), pp.303-307.

DOI: https://doi.org/10.1016/s0924-0136(03)00771-4

[6] A. Banu, M.Y. Ali and M.A. Rahman: Micro-electro discharge machining of non-condcutive zirconia ceramic: investigation of MRR and recast layer hardness. International Journal of Advanced Manufacturing Technology, 75 (1-4) (2014), pp.257-267.

DOI: https://doi.org/10.1007/s00170-014-6124-9

[7] T. Hosel, T. Cvancara, T. Ganz, C. Muller and H. Reinecke: Characterization of high aspect ratio non-conductive ceramic microstructures made by spark erosion. Microsystem Technologies, 17 (2011), p.313–318.

DOI: https://doi.org/10.1007/s00542-011-1284-0

[8] T. Hosel, C. Muller and H. Reinecke: Spark erosive structuring of electrically nonconductive zirconia with an assisting electrode. CIRP Journal of Manufacturing Science and Technology, 4 (2011), pp.357-361.

DOI: https://doi.org/10.1016/j.cirpj.2011.05.005

[9] A. Muttamara, Y. Fukuzawa, N. Mohri and T. Tani: Effect of electrode material on electrical discharge machining of alumina. Journal of Materials Processing Technology, 209 (2009), pp.2545-2552.

DOI: https://doi.org/10.1016/j.jmatprotec.2008.06.018

[10] Y. Guo, L. Wang, G. Zhang, and P. Hou: Multi-response optimization of the electrical discharge machining of insulating zirconia. Material and Manufacturing Processes, 32 (3) (2017), pp.294-301.

DOI: https://doi.org/10.1080/10426914.2016.1176180

[11] Y. Pachaury and P. Tandon: An overview of electric discharge machining of ceramics and ceramic based composites. Journal of Manufacturing Processes, 25 (2017), pp.369-390.

DOI: https://doi.org/10.1016/j.jmapro.2016.12.010

[12] B. Asfana, M.Y. Ali, A.R. Mohamed and W.N. Hung: Material removal rate of zirconia in electro discharge micromachining. Advanced Materials Research, 1115 (2015), pp.20-23.

DOI: https://doi.org/10.4028/www.scientific.net/amr.1115.20

[13] R. Ji, Y. Liu, Y. Zhang, F. Wang, Z. Chen and X. Dong: Study on single-discharge machining characteristics of non-conductive engineering ceramics in emulsion with high open voltage and large capacitor. Journal of Engineering Manufacture, 1-12 (2011).

DOI: https://doi.org/10.1177/0954405411404630

[14] B. Lauwers, J.P. Kruth, W. Liu, W. Eeraerts, B. Schacht and P. Bleys: Investigation of material removal mechanisms in EDM of composite ceramic materials. Journal of Materials Processing Technology, 149 (2004), pp.347-352.

DOI: https://doi.org/10.1016/j.jmatprotec.2004.02.013

[15] G. Kucukturk and C. Cogun: A new method for machining of electrically nonconductive workpieces using electrical discharge machining technique. Machining Science and Technology, 14 (2010), pp.189-207.

DOI: https://doi.org/10.1080/10910344.2010.500497

[16] A. Muttamara, Y. Fukuzawa and K. Aursatitwong: Feasibility study for slit machining using EDM on silicon nitride. 2nd International Conference on Mechanical, Production and Automobile Engineering (ICMPAE'2012), Singapore (2012).

[17] N. Mohri, Y. Fukuzawa, T. Tani, N. Saito and K. Furutani: Assisting electrode method for machining insulating ceramics. Annals of the CIRP, 45 (1996), pp.201-204.

DOI: https://doi.org/10.1016/s0007-8506(07)63047-9

[18] Y.H. Liu, X.P. Li, R.J. Ji, L.L. Yu, H.F. Zhang and Q.Y. Li: Effect of technological parameter on the process performance for electric discharge milling of insulating Al2O3 ceramic. Journal of Materials Processing Technology, 208 (2008).

DOI: https://doi.org/10.1016/j.jmatprotec.2007.12.143

[19] M. Zahiruddin and M. Kunieda: Comparison of energy and removal efficiencies between micro and macro EDM. CIRP Annals-Manufacturing Technology, 61 (1) (2012), pp.187-190.

DOI: https://doi.org/10.1016/j.cirp.2012.03.006

[20] M.P.S. Krishna Kiran and S.S. Joshi: Modeling of surface roughness and the role of debris in micro-EDM. Journal of Manufacturing Science and Engineering, 129 (2) (2007), pp.265-273.

DOI: https://doi.org/10.1115/1.2540683

[21] K. Salonitis, A. Stournaras, P. Stavropoulos and G. Chryssolouris: Thermal modeling of the material removal rate and surface roughness for die-sinking EDM. The International Journal of Advanced Manufacturing Technology, 40 (3-4) (2009).

DOI: https://doi.org/10.1007/s00170-007-1327-y

[22] Q. Zhang, R. Du, J. Zhang and Q. Zhang: An investigation of ultrasonic-assisted electrical discharge machining in gas. International Journal of Machine Tools and Manufacture, 46 (12) (2006), pp.1582-1588.

DOI: https://doi.org/10.1016/j.ijmachtools.2005.09.023