Si3N4–TiN conductive ceramic composites: topography on EDMed surfaces and precise drilled holes

Abstract

In this study, it is challenging to drill a 5 mm hole in a Si3N4–TiN conductive ceramic composite, specifically when attempting to identify an association between EDM machining inputs such as current, pulse on-time, pulse off-time, dielectric pressure and spark gap and performance parameters like as Material Removal Rate, Electrode Wear Rate, Average Surface Roughness, and geometrical tolerances such as Cylindricity, Circularity and perpendicularity. The study examines the surface deformations of a composite comprising EDAX report, machined electrode and molybdenum wire following WEDM machining. Current of 5A, Pulse on-time of 9µs, Pulse off-time of 7µs, spark gap of 0.15 mm, dielectric pressure of 21.0 kg/cm2, material removal rate of 0.004214 g/min, electrode wear rate of 0.000245 g/min and surface roughness of 0.349 µm were found to be optimal. The experimental findings show that good surface finish may be attained on a copper electrode-machined surface, along with improved machining accuracy, closer geometrical tolerances and lesser anomalies.