Material removal mechanism of alumina ceramics with powder-mixed electrochemical discharge-drilling hybrid machining

IF 5.1 2区材料科学 Q1 MATERIALS SCIENCE, CERAMICS

Ceramics International Pub Date : 2025-04-01 DOI:10.1016/j.ceramint.2025.01.152

Yuanqiang Luo , Quancai Zhao , Weidong Tang , Cong Mao , Longzhou Dai , Jize Zhang , Jikai Yao , Abdur Razzak , Xiaoming Kang

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引用次数: 0

Abstract

Engineering ceramics have excellent properties such as high hardness and strength, resistance to high temperature, wear and corrosion, However, these ceramics also pose great challenges to processing techniques. A novel method of powder-mixed electrochemical discharge-drilling hybrid machining (PMECDDM) for alumina ceramics was proposed in this paper. The thermal removal mechanism of alumina ceramics during the hybrid machining process were analyzed. The temperature distribution on alumina ceramics under the action of the single-pulse electrochemical discharge was obtained based on a thermal-fluid coupling multiphysics simulation model. The axial force during the material removal process in mechanical drilling (MD) was comprehensively analyzed. Experiments were conducted under constant force feed condition to investigate the micro-hole machining performance of alumina ceramics by different machining methods. Experimental results revealed that a new form of discharge was generated after the introduction of the micro copper powder into the electrochemical discharge-mechanical drilling hybrid machining process, which increased the local discharge energy and strengthens the softening effect of the discharge on alumina ceramics. Compared to MD, the machined surface of PMECDDM exhibited fewer brittle fracture areas, resulting in improved surface quality. Compared with the conventional electrochemical discharge-drilling hybrid machining (ECDDM), the machining efficiency of PMECDDM was increased by approximately 47 %.

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粉末-混合电化学放电-钻孔复合加工氧化铝陶瓷材料去除机理

工程陶瓷具有高硬度、高强度、耐高温、耐磨损、耐腐蚀等优良性能，但其加工工艺也面临着巨大的挑战。提出了一种新型的氧化铝陶瓷粉末-混合电化学放电-钻孔复合加工方法。分析了复合加工过程中氧化铝陶瓷的热去除机理。基于热流耦合多物理场仿真模型，得到了单脉冲电化学放电作用下氧化铝陶瓷表面的温度分布。对机械钻孔材料去除过程中的轴向力进行了综合分析。在恒进给力条件下，研究了不同加工方法对氧化铝陶瓷微孔的加工性能。实验结果表明，在电化学放电-机械钻孔复合加工过程中引入微量铜粉后，产生了一种新的放电形式，增加了局部放电能量，增强了放电对氧化铝陶瓷的软化作用。与MD相比，PMECDDM的加工表面具有更少的脆性断裂区域，从而提高了表面质量。与传统的电化学放电-钻孔混合加工（ECDDM）相比，PMECDDM的加工效率提高了约47%。

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来源期刊

Ceramics International 工程技术-材料科学：硅酸盐

CiteScore

9.40

自引率

15.40%

发文量

4558

审稿时长

25 days

期刊介绍： Ceramics International covers the science of advanced ceramic materials. The journal encourages contributions that demonstrate how an understanding of the basic chemical and physical phenomena may direct materials design and stimulate ideas for new or improved processing techniques, in order to obtain materials with desired structural features and properties. Ceramics International covers oxide and non-oxide ceramics, functional glasses, glass ceramics, amorphous inorganic non-metallic materials (and their combinations with metal and organic materials), in the form of particulates, dense or porous bodies, thin/thick films and laminated, graded and composite structures. Process related topics such as ceramic-ceramic joints or joining ceramics with dissimilar materials, as well as surface finishing and conditioning are also covered. Besides traditional processing techniques, manufacturing routes of interest include innovative procedures benefiting from externally applied stresses, electromagnetic fields and energetic beams, as well as top-down and self-assembly nanotechnology approaches. In addition, the journal welcomes submissions on bio-inspired and bio-enabled materials designs, experimentally validated multi scale modelling and simulation for materials design, and the use of the most advanced chemical and physical characterization techniques of structure, properties and behaviour. Technologically relevant low-dimensional systems are a particular focus of Ceramics International. These include 0, 1 and 2-D nanomaterials (also covering CNTs, graphene and related materials, and diamond-like carbons), their nanocomposites, as well as nano-hybrids and hierarchical multifunctional nanostructures that might integrate molecular, biological and electronic components.