Problems and solutions of composite machining by electro-diamond methods for materials based on zirconium diboride
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-02-28 |
| Journal | Science intensive technologies in mechanical engineering |
| Authors | Andrey Yanyushkin, Dmitry Lobanov, Aleksandr Yanyushkin, Vladimir V. Skripnyak, Vladimir A. Skripnyak |
| Institutions | National Research Tomsk State University, Chuvash State University |
| Analysis | Full AI Review Included |
Technical Documentation: Advanced Machining of Zirconium Diboride (ZrB2) Composites
Section titled âTechnical Documentation: Advanced Machining of Zirconium Diboride (ZrB2) CompositesâExecutive Summary
Section titled âExecutive SummaryâThis documentation analyzes the application of combined electro-diamond grinding for machining ultra-hard Zirconium Diboride (ZrB2) ceramic composites, highlighting the critical role of high-quality diamond materials and advanced process control.
- Challenge Addressed: Traditional machining of high-strength ceramic composites (like ZrB2, melting point > 3000 °C, high hardness) is difficult or impossible due to material hardness comparable to abrasives.
- Solution Implemented: Modernization of a PP600F machine to perform combined electro-diamond grinding using diamond wheels on a metallic binder (AC6 125/100 M1).
- Key Innovation: Continuous electrochemical truing (dressing) of the diamond wheel, enabling a stable self-sharpening mode by controlling cutting power and current density.
- Performance Improvement: Diamond wheel consumption was reduced by a factor of 3 to 4 times compared to conventional grinding methods.
- Quality Achieved: Guaranteed absence of micro and macro cracks, achieving a final surface roughness (Ra) between 0.2 ”m and 0.4 ”m.
- 6CCVD Relevance: The success of this method relies on high-performance diamond tooling and specialized electrochemical components, areas where 6CCVD provides custom MPCVD Single Crystal (SCD), Polycrystalline (PCD), and Boron-Doped Diamond (BDD) materials.
Technical Specifications
Section titled âTechnical SpecificationsâThe following parameters were established as rational cutting modes for combined electro-diamond grinding of ZrB2 ceramics:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Workpiece Material | Zirconium Diboride (ZrB2) Ceramic Composite | N/A | Ultra-high strength ceramic |
| Diamond Wheel Type | AC6 125/100 M1 | N/A | Metallic binder, 100% concentration |
| Wheel Speed ($V_{gwh}$) | 35 | m/s | Grinding velocity |
| Longitudinal Feed ($S_{pr}$) | 0.5 - 1.5 | m/min | Workpiece feed rate |
| Cross Feed ($S_{non}$) | 0.02 - 0.05 | mm/dv.stroke | Depth of cut per double stroke |
| Truing Current Density ($i_{np}$) | 0.2 - 0.6 | A/cm2 | Current density for continuous electrochemical truing |
| Etching Current Density ($i_{tr}$) | 4 - 6 | A/cm2 | Current density for surface etching/cleaning |
| Final Surface Roughness (Ra) | 0.2 - 0.4 | ”m | Achieved surface quality (absence of micro/macro cracks) |
| Diamond Consumption | 1.0 - 1.5 | mg/g | Specific consumption rate (3-4x reduction vs. traditional) |
| Power Source Frequency | 50 Hz, or 10-3 - 10-7 Hz | N/A | Industrial frequency or pulsed mode for technological current |
Key Methodologies
Section titled âKey MethodologiesâThe research successfully implemented and optimized a combined electro-diamond processing technique, focusing on maintaining the cutting capacity of the metallic-binder diamond wheel.
- Machine Modernization: A standard PP600F grinding machine was modified to enable combined electro-diamond processing. This included developing specialized components:
- Current collector (using three spring-loaded graphite brushes).
- Cathode structure for continuous wheel truing.
- Technological current source (capable of 50 Hz and pulsed 10-3 to 10-7 Hz operation).
- Automatic control system for the truing current.
- Self-Sharpening Mode Stabilization: The core methodology relies on stabilizing the cutting power. When the wheel loses cutting ability, cutting power increases, triggering the automatic control unit.
- Electrochemical Truing (Dressing): Upon reaching a critical power/force threshold, the control unit activates the truing circuit. This involves anodic dissolution of the metallic binder and the clogged layer of the grinding wheel using an electrolyte supplied through the cathode.
- Abrasive Grain Renewal: The dissolution of the binder exposes fresh diamond grains, restoring the wheelâs cutting capacity and reducing cutting power, thus maintaining continuous self-sharpening operation.
- Quality Verification: Experiments utilized standard optical and electron microscopy to confirm the absence of surface defects (micro/macro cracks) and verify the achieved surface roughness (Ra 0.2-0.4 ”m).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe successful machining of ultra-hard materials like ZrB2 requires diamond components with exceptional purity, consistency, and customizable geometry. 6CCVD is uniquely positioned to supply the foundational MPCVD diamond materials and custom components necessary to replicate and advance this research.
Applicable Materials
Section titled âApplicable MaterialsâThe combined electro-diamond method requires two primary diamond material types: high-performance abrasives (used in the wheel) and robust electrochemical components (used in the truing/etching system).
| Research Requirement | 6CCVD Material Solution | Technical Rationale & Application |
|---|---|---|
| High-Performance Abrasives | Polycrystalline Diamond (PCD) | Ideal for manufacturing high-concentration diamond wheels and cutting inserts used in machining ultra-hard ceramics. 6CCVD offers PCD plates up to 125mm in diameter. |
| Electrochemical Components | Boron-Doped Diamond (BDD) | BDD is the premier electrode material due to its extreme chemical stability, wide potential window, and high conductivity. Essential for the cathode/anode components used in the continuous electrochemical truing process ($i_{np}$ and $i_{tr}$). |
| High-Purity Wear Parts | Single Crystal Diamond (SCD) | For critical wear surfaces or high-precision tooling components within the grinding system requiring Ra < 1nm and maximum thermal stability. |
Customization Potential
Section titled âCustomization PotentialâThe modernization described in the paper requires specialized components (current collectors, cathodes, custom tooling). 6CCVDâs in-house capabilities directly support the engineering and manufacturing of these advanced parts.
- Custom Dimensions: 6CCVD can supply SCD and PCD plates/wafers in custom dimensions and thicknesses (SCD/PCD up to 500 ”m, substrates up to 10 mm) required for specialized grinding tools or electrochemical cells.
- Electrode Fabrication: We offer custom BDD wafers tailored for use as high-efficiency electrodes in the electrochemical truing system, ensuring precise current density control (0.2-0.6 A/cm2) and long operational life in aggressive electrolytes.
- Advanced Metalization: The paperâs methodology relies on electrical contact and current flow. 6CCVD provides internal metalization services (Au, Pt, Pd, Ti, W, Cu) crucial for creating reliable electrical contacts on BDD electrodes and for integrating diamond components into complex metallic tooling structures.
- Precision Polishing: For any diamond components requiring ultra-low friction or high optical quality, 6CCVD guarantees polishing down to Ra < 1nm (SCD) and Ra < 5nm (inch-size PCD).
Engineering Support
Section titled âEngineering SupportâThe successful implementation of combined electro-diamond grinding for high-strength ceramic materials like ZrB2 requires deep expertise in both material science and process engineering.
- Material Selection Expertise: 6CCVDâs in-house PhD team specializes in the properties and applications of MPCVD diamond. We can assist engineers in selecting the optimal diamond grade (SCD, PCD, or BDD) and geometry for similar ultra-hard material processing projects, ensuring maximum tool life and surface quality (Ra 0.2-0.4 ”m).
- Global Supply Chain: We offer reliable global shipping (DDU default, DDP available) to ensure researchers and manufacturers worldwide receive their custom diamond materials quickly and efficiently.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
Problematic issues related to the development, machinability and application of new high-strength ceramic materials are viewed. Such materials possess high hardness comparable to the hardness of abrasive materials. Therefore, it makes difficult to produce such materials using traditional techniques. To solve this problem, we have proposed the modernization of the PP 600F machine with the implementation of combined electro-diamond processing of high-strength ceramic materials with diamond wheels on a binder metal. The modernization provides for the development of special components and structures of a current collector, a cathode for straightening a circle, a circuit for a technological current source and constructive solutions for automatic control of the straightening current. Based on the results of the study, rational cutting modes have been established to guarantee the quality of products made of high-strength composite materials. The experiments were performed with standard techniques using optical and electron microscopy. The tasks were solved taking into account the study of diamond wheels flow density on a metallic binder, as well as forces, power, cutting temperature, defects on the surface of the grinding wheel and the machined product. The solution for controlling the cutting capacity of a grinding wheel and the conditions of their operation in the self-sharpening mode is shown. Based on the stabilization of cutting power, the self-sharpening mode of diamond wheels on a metallic binder and grinding modes are switched on:Vgwh = 35 m/s; Spr = 0.5.1.5 m/min; Spr = 0,5âŠ1,5 m/min; Spop = 0,02âŠ0,05 mm/dv.stroke ipr = 0,2âŠ0,6 A/cm2; itr = 4âŠ6A/cm2. Using the example of grinding zirconium diboride with an A C 6 diamond wheel with a grain size of 125/100 in these modes, it guarantees the absence of micro, macro cracks, and the roughness of the machined surface within 0.2âŠ0.4 microns.