Department of Mechanical Engineering, College of Engineering and Islamic Architecture, Umm Al-Qura University, Makkah, 24224, Saudi Arabia.
Department of Mechanical Engineering, Mahendra Institute of Technology (Autonomous), Namakkal District, Tamil Nadu, 637 503, India.
J Mech Behav Biomed Mater. 2023 Dec;148:106166. doi: 10.1016/j.jmbbm.2023.106166. Epub 2023 Oct 10.
The novel applications of MoSi and SiC as matrix and reinforcing materials in the creation of high-performance composites were investigated in this work. In particular, Spark Erosion Machining's geometric tolerances were studied in order to shed light on the technique's potential for precision manufacture in the realm of MoSi-SiC composites. Our research focused on evaluating critical parameters and their impact on machining performance, including material removal rate, surface roughness, wear rate and drilled hole accuracy. In-depth research revealed the critical input factors that had the greatest impact on the machining procedure. Notably, parameters such as current (32%), sparking on time (23%), sparking gap voltage (12%), dielectric pressure (12%), and sparking off time (17%) emerged as the most influential factors, as determined by ANOVA analysis. These findings provide valuable insights into optimizing the Sparking EDM approach for MoSi-SiC composite materials. This study further demonstrated the improvement in composite desirability ratings across multiple performance criteria, highlighting the effectiveness of Sparking EDM in enhancing machining outcomes (e.g., from 0.8523 to 0.9527). Correlations between the EDM's output responses were found to be quite high when geometric tolerances and the coefficient of determination (R2) were used (0.7858, 0.9625, 0.8427, 0.8678, 0.8474, 0.8368, 0.8344, 0.8671). Consider that, for the sake of a more complete understanding of the procedure's approach, the emphasis is on the methodology rather than the multifaceted metal removal mechanisms involved. This research doesn't dive further into the physical concerns of Spark Erosion Machining, but it does provide insights into the practical application of this technique in the precision manufacturing of MoSi2-SiC composite materials. For real-world medical applications such implanted devices, dental implants, surgical instruments, biological sensors and diagnostics, this study provides a valuable and encouraging approach. A validation experiment verifies the results, proving the feasibility of improved spark erosion in high-precision production. The results of this research show that EDM methods can be fine-tuned to produce ceramic composites with much greater MRR, superior surface finishes and a marked decrease in subsurface cracking and microstructural modifications. This is essential for protecting the integrity of materials used in life-saving medical equipment.
本工作研究了 MoSi 和 SiC 作为基体和增强材料在高性能复合材料中的新应用。特别是，研究了火花侵蚀加工的几何公差，以揭示该技术在 MoSi-SiC 复合材料精密制造领域的潜力。我们的研究重点是评估关键参数及其对加工性能的影响，包括材料去除率、表面粗糙度、磨损率和钻孔精度。深入研究揭示了对加工过程影响最大的关键输入因素。值得注意的是，通过方差分析，电流（32%）、火花导通时间（23%）、火花间隙电压（12%）、介电压力（12%）和火花关断时间（17%）等参数被确定为最具影响力的因素。这些发现为优化 MoSi-SiC 复合材料的火花放电加工方法提供了有价值的见解。本研究进一步证明了在多个性能标准下提高了复合材料的可接受性评分，突出了火花放电加工在提高加工效果方面的有效性（例如，从 0.8523 提高到 0.9527）。当使用几何公差和确定系数（R2）时，发现电火花加工的输出响应之间存在相当高的相关性（0.7858、0.9625、0.8427、0.8678、0.8474、0.8368、0.8344、0.8671）。需要注意的是，为了更全面地了解该方法的过程，重点是方法而不是涉及的多方面金属去除机制。本研究没有进一步深入探讨火花侵蚀加工的物理问题，但它为这项技术在 MoSi2-SiC 复合材料的精密制造中的实际应用提供了一些见解。对于植入设备、牙科植入物、手术器械、生物传感器和诊断等实际的医疗应用，本研究提供了一种有价值且令人鼓舞的方法。验证实验验证了结果，证明了在高精度生产中改进火花侵蚀的可行性。研究结果表明，电火花加工方法可以进行微调，以生产出具有更高 MRR、更好表面光洁度、显著减少亚表面裂纹和微观结构变化的陶瓷复合材料。这对于保护救生医疗设备中使用的材料的完整性至关重要。
