Journal of Materials Processing Technology 153–154 (2004) 1033–1038

A study on the electrical discharge machining of conductive ceramics

I. Puertas∗ , C.J. Luis
Department of Mechanical Engineering, Manufacturing Engineering Section, Public University of Navarre (Spain),
Campus de Arrosadı́a s/n, Pamplona (Navarre), Navarre 31006, Spain

Abstract

In this work, a comparative study of the electrical discharge machining (EDM) of three different conductive ceramics has been carried out.
The ceramics used in the experiments were cobalt-bonded tungsten carbide (WC–Co), hot-pressed boron carbide (B4 C) and reaction-bonded
silicon carbide (SiSiC). This study has been done only for the finishing stages and the selection of the above-mentioned conductive ceramics
was motivated by their wide range of applications: machining and mining for WC–Co, thermal-neutron absorber and nozzles for B4 C
and wear parts and heat exchangers for SiSiC, among others. The comparative study has been carried out on the influence of the design
factors of intensity (I), pulse time (ti ) and duty cycle (η) over response variables such as surface roughness (evaluated through the Ra
parameter), volumetric electrode wear (EW) and material removal rate (MRR). This was accomplished through the technique of design of
experiments (DOE), along with multiple linear regression techniques, which allowed us to carry out the analysis with only a small number
of experiments.
© 2004 Elsevier B.V. All rights reserved.

Keywords: Die-sinking EDM; Conductive ceramics; Surface roughness; DOE

1. Introduction terials. In line with current knowledge, the main inconve-

At present, EDM is a widespread technique used in
industry for high-precision machining of all types of con-
ductive materials such as metals, metallic alloys, graphite,
or even some ceramic materials, of whatever intensity of
hardness [1].
The term, technical ceramic materials or advanced ce-
ramic materials, is a relatively new term, which is applied
to a range of various materials generally obtained from
inorganic primary materials with a high grade of purity.
These primary materials are subjected to typical processes
in powder metallurgy technology and afterwards, to high
temperature sintering processes. With these materials, it is
possible to obtain high-density parts which have good tech-
nical properties related to hardness, mechanical resistance,
wear and corrosion at high temperatures [2].
In spite of their exceptional mechanical and chemical
properties, ceramic materials have only achieved a partial
acceptance in the field of industrial applications due to the
difficulties in processing and the high costs associated with
their manufacture. Over the past few years, the advances
in the field of EDM have permitted the application of this
technology to the manufacture of conductive ceramic ma-
∗ Corresponding author.
E-mail address: inaki.puerta@unavarra.es (I. Puertas).
nience when applying the EDM technology to the field of
ceramic materials, is the electrical resistivity of these mate-
rials, where the limits are fixed between 100 and 300  cm
[3].
In this work, a comparative study has been carried out cen-
tred solely on the experience of the die-sinking EDM of three
different ceramic materials and for finishing stages. The
selected materials were hot-pressed boron carbide (B4 C),
reaction-bonded silicon carbide (SiSiC) and cobalt-bonded
tungsten carbide (WC–Co), whose fields of applications are
in constant growth. Accordingly, a comparative analysis has
been carried out on the influence of intensity, pulse time and
duty cycle on important technological variables such as sur-
face roughness (Ra ), volumetric electrode wear (EW) and
material removal rate (MRR). This was accomplished us-
ing the technique of design of experiments (DOE) and tech-
niques of multiple linear regression analysis.
2. Description of the experiments
2.1. EDM machine used
The equipment used was a die-sinking EDM machine of
type ONA DATIC D-2030-S. The only modification which
was made to the original equipment was the adaptation of a

0924-0136/$ – see front matter © 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2004.04.197
1034 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038
microfine control, which allowed us to obtain a mirror-type
surface finish for the case of steels. This additional equip-
ment consists of a series of stages formed by capacitors,
which provide variable capacity between the part and the
electrode.
2.2. Ceramic material of boron carbide (B4 C)
The first ceramic material used in the experiments was
hot-pressed boron carbide (B4 C). It has excellent properties
of hardness (37 GPa), resistance to wear as well as fracture
toughness (3–4 MPa m1/2 ). Its density is low (2.50 g/cm3 )
but, on the other hand, it has a high compressive strength
(2855 MPa) and a high module of elasticity (445 GPa), which
makes its use as ballistic material one of its widest applica-
tions. As 20% of natural boron is made up of the isotope of
boron B10 , it presents a high neutron capture cross-section
and so is usually used in neutron absorption applications
such as lining in nuclear fission reactors.
The samples of boron carbide used in the experi-
ments were ground sheets of the following dimensions:
50 mm × 50 mm × 4 mm. Moreover, the electrodes used
were made of electrolytic copper as it is the most highly
recommended material for the EDM process of boron car-
bide [4,5]. The selected copper electrodes (with positive
polarity for B4 C) used in this study for all the ceramic ma-
terials were of a prismatic shape and with a cross section of
8 mm × 12 mm.
2.3. Ceramic material of silicon carbide (SiSiC)
The second ceramic material used in this work was
reaction-bonded or siliconised silicon carbide (REFEL F® ).
The mechanical resistance (2000–3500 MPa to compres-
sion and 310 MPa to tension) combined with a hardness
(25–35 GPa, Vickers hardness) which is higher than that
of tungsten carbide explains its use as an element in high
temperature gas turbines as well as forming part of bear-
ings and seals. Furthermore, it has a high thermal con-
ductivity (150–200 W m−1 K−1 , at 20 ◦ C) and a thermal
expansion coefficient (4.3–4.6 × 10−6 K−1 , for an interval
of 20–1000 ◦ C) which gives it good resistance to thermal
shock. Reaction-bonded silicon carbide performs better un-
der chemical corrosion than other ceramic materials such
as tungsten carbide or alumina (Al2 O3 ). It is therefore
frequently used as lining for industrial furnaces.
The samples of silicon carbide were ground sheets of
dimensions: 50 mm × 50 mm × 5 mm. As in the case of
the earlier ceramic material, the electrodes used were made
of electrolytic copper, as, according to the bibliographic
sources consulted [6,7], it is the most highly recommended
material for the EDM of silicon carbide. Conversely, the
use of negative polarity for the electrode is recommended
for this material, as the machining process can therefore be
carried out in a more stable way.
2.4. Ceramic material of tungsten carbide (WC–Co)
The third material used in the experiments was 94WC–6Co
tungsten carbide. This material was principally developed
in order to be used as cutting tool, due to its excellent
hardness properties (HRA 92). Furthermore, it possesses
a high compressive strength (5450 MPa), as well as good
resistance to wear and oxidation at high temperatures. On
the other hand, the compound material made up of tung-
sten carbide and cobalt has a high resistance to thermal
shock and, consequently, it is capable of coping with rapid
changes of temperature. In the case of 94WC–6Co, it has a
thermal conductivity of 100 W/m K and a thermal expansion
coefficient of 4.3 × 10−6 K−1 , at a temperature of 200 ◦ C.
At present, although approximately 50% of the manufac-
turing of this type of cemented carbides is used in machin-
ing applications, the number of alternative applications is
quickly growing, where the most important areas are mining,
construction, transport and drilling in oil and gas installa-
tions, metal forming, structural components and as material
for tools in the field of forestry engineering.
The samples of tungsten carbide were ground sheets of
dimensions: 50 mm × 50 mm × 4 mm. As in the two pre-
vious cases, the electrodes used were made of electrolytic
copper because, according to the bibliographic sources con-
sulted [7,8], it is the most highly recommended material for
the EDM of tungsten carbide. Furthermore, it is also rec-
ommended that negative polarity for the electrode should
be used in order to ensure a much more stable machining
process.
2.5. Design factors
There are a large number of factors to consider within
the EDM process, but in this work we have only considered
the generator intensity (I), pulse time (ti ) and duty cycle
(η). The reason why these three factors have been selected
as design factors is that they are the most widespread and
frequently-used ones among EDM researchers.
2.6. Response technological variables
The response variables studied in this work were surface
roughness, material removal rate and electrode wear. The
previous variables were chosen because of their importance
within the EDM research field.
The surface roughness parameter which was selected as
a response variable was the arithmetic average roughness of
the roughness profile (Ra ). This surface roughness parame-
ter is defined in accordance with UNE-EN-ISO 4287: 1999.
When carrying out the surface roughness measurements over
the ceramic materials, a phase corrected 2CR filter was se-
lected for the rugosimeter, along with a length of measure-
ment of 6.4 mm (8 mm × 0.8 mm). Moreover, a stylus tip
radius of 3 ␮m, a stylus speed of 1 mm/s and a stylus static
force of 0.12 mN were used.
 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038
In addition to surface roughness, material removal rate
(MRR) and electrode wear (EW) were studied. Although
there are other ways of measuring material removal rate, in
this work we have obtained the MRR values through the
weight difference of the sample before and after undergoing
the EDM process. Furthermore, when calculating the values,
it was accepted that the densities of the ceramic materials
were 2.50 g/cm3 (B4 C), 3.10 g/cm3 (SiSiC) and 14.95 g/cm3
(WC–Co), in accordance with the information from the man-
ufacturer.
Although the concept of electrode wear can be defined in
many different ways, in this current study we have selected
the definition of electrode wear according to the differences
in the volumes of the electrode and the part, as this def-
inition is the most commonly used among researchers. In
order to calculate the loss of material from the electrode,
we have used the same technique mentioned earlier and we
have taken a density value of 8.96 g/cm3 for the case of elec-
trolytic copper, in line with the information from the man-
ufacturer.
3. Design of the experiments
The design which was finally chosen was a factorial de-
sign 23 with four central points, which provide protection
against curvature, and a total of 12 experiments were made
[9,10]. Consequently, for the case of the response variables
which were not adequate for the previous first order model,
this was widened by the addition of six star points, giving
then a central composite design made up of the star points
situated in the centres of the faces; that is to say, a total of
18 experiments in the case of this second order model.
Table 1 presents the relationship between factors and their
selected variation levels, taking into consideration that the
study wanted to focus on the case of finishing machining
stages.
Table 2 shows the design matrix resulting from the type of
experiment selected in the case of the second order model,
as well as the observations for the case of the three response
variables which are considered in this study, where the in-
tensity values 3, 4 and 5 are equivalent to 2A, 4A and 6A,
respectively. The design matrix for the first order model is
obtained by merely eliminating the rows corresponding to
the star points of the model.
After having performed a series of curvature tests for each
of the ceramic materials and each of their corresponding
Table 1
Factors and levels selected for the experiments
Factors Levels
−1
I 3
ti (␮s) 10
η 0.4
1035
Fig. 1. Comparison of the I factor effect over Ra for the different ceramic
materials.
response variables, second order models were selected for
all the cases, except for the Ra parameter of boron carbide
and the MRR variable of silicon carbide.
4. Comparative analysis of ceramic materials
4.1. Comparative analysis of the Ra parameter
Fig. 1 shows the intensity factor effect over the Ra param-
eter for the ceramic materials considered in this study.
As can be observed in Fig. 1, in both silicon carbide and
tungsten carbide the Ra parameter tends to increase signif-
icantly when intensity increases. Conversely, in the case of
boron carbide Ra this tends to decrease with the increase in
intensity although, in this case, this factor does not turn out
to be statistically significant for the considered confidence
level. In practice, this diminution tendency in the Ra param-
eter with the intensity factor is exactly the opposite of what
would be expected a priori, as increases in pulse energy are
usually associated, by and large, with a worsening in the
material surface roughness.
Fig. 2 shows the pulse time effect over the Ra parameter
for the different ceramic materials under study.
As can be seen in Fig. 2, the Ra parameter tends to in-
crease when pulse time is increased for all the considered
materials. The most notable increase is produced for boron
carbide, the effect of this factor being rather less significant
in the case of silicon carbide. Furthermore, in this latter case
the Ra parameter seems to tend to decrease somewhat for
+1
5
50
0.6 Fig. 2. Comparison of the ti factor effect over Ra for the different ceramic
materials.
1036 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038

Table 2
Design of experiment matrix obtained for the case of the second order model
Number I ti (␮s) η B4 C SiSiC WC–Co

Ra (␮m) EW (%) MRR Ra (␮m) EW (%) MRR Ra (␮m) EW (%) MRR

(mm3 /min) (mm3 /min) (mm3 /min)
1 3 10 0.4 1.38 1.93 0.135 0.89 9.47 0.092 0.66 36.51 0.055
2 5 10 0.4 1.30 3.10 0.187 1.09 8.80 0.213 1.24 15.32 0.248
3 3 50 0.4 2.27 0.26 0.159 0.75 16.18 0.024 0.66 71.58 0.012
4 5 50 0.4 2.16 0.59 0.206 1.17 8.92 0.118 1.93 12.09 0.202
5 3 10 0.6 1.41 2.07 0.328 0.86 10.60 0.139 0.65 35.25 0.090
6 5 10 0.6 1.26 3.38 0.357 1.23 11.82 0.331 1.37 15.54 0.428
7 3 50 0.6 2.03 0.30 0.339 0.82 14.90 0.043 0.64 71.77 0.020
8 5 50 0.6 2.06 0.39 0.396 1.86 8.04 0.378 2.02 11.09 0.318
9 3 30 0.5 1.56 1.04 0.183 0.84 13.03 0.047 0.64 66.41 0.026
10 5 30 0.5 1.68 0.80 0.261 1.34 8.92 0.234 1.75 11.02 0.279
11 4 10 0.5 1.34 2.84 0.290 1.20 8.07 0.339 1.11 17.34 0.236
12 4 50 0.5 1.92 0.50 0.250 1.26 8.25 0.159 1.73 15.21 0.155
13 4 30 0.4 1.68 1.01 0.171 1.24 8.17 0.147 1.43 14.93 0.147
14 4 30 0.6 1.51 0.91 0.341 1.34 8.68 0.254 1.54 13.35 0.246
15 4 30 0.5 1.77 0.77 0.283 1.34 8.42 0.190 1.43 14.29 0.193
16 4 30 0.5 1.83 0.69 0.282 1.33 8.45 0.192 1.34 14.15 0.192
17 4 30 0.5 1.77 1.02 0.277 1.30 8.59 0.180 1.39 14.08 0.194
18 4 30 0.5 1.78 0.88 0.274 1.37 8.29 0.203 1.42 14.09 0.194

pulse time values close to its highest level of 50 ␮s. There-
fore, the tendency of Ra with regard to this design factor
is exactly what would be expected a priori, as decreasing
the frequency of the pulse usually leads to worse values of
surface roughness.
Fig. 3 shows a comparative graph of the duty cycle effect
over the Ra parameter for the three ceramic materials studied
in this work. As can be observed in this figure, in the cases
of silicon carbide and tungsten carbide, the Ra parameter
increases when duty cycle is increased, especially for silicon
carbide, while this effect is not statistically significant for
tungsten carbide, within the considered confidence level.
In the case of boron carbide, the Ra parameter tends to de-
crease lightly when duty cycle is increased, although, in this
case, the effect of this factor is not statistically significant
for the confidence level under consideration in this study. On
the other hand, this tendency of the Ra parameter to decrease
when duty cycle increases, within the considered work in-
terval, is exactly the opposite of what would be expected in
practice, as, when pause time tends to decrease, which is
equivalent to increasing the duty cycle factor if pulse time
remains constant, surface finish tends to worsen because the
stability of the process is affected.
4.2. Comparative analysis of the electrode wear EW
Fig. 4 shows the main effect of the intensity factor over
the response variable of EW, for the different materials con-
sidered in this study. In the case of boron carbide, the elec-
trode wear tends to increase when intensity increases. On
the contrary, in the cases of silicon carbide and tungsten car-
bide, the wear value decreases significantly, with intensity
down to a minimum value after which the electrode wear
increases with the increase in the previous factor. In prac-
tice, the logical tendency to expect, a priori, would be of a
decrease in the electrode wear as we move towards stages
with greater pulse energy, that is, growing intensity levels.
Fig. 5 shows the effect of the pulse time factor over the
EW variable for the different ceramic materials. As can be
seen in Fig. 5, in the case of boron carbide, the electrode
wear value tends to decrease greatly with an increase in pulse
time, which coincides with the behaviour which would be

Fig. 3. Comparison of the η factor effect over Ra for the different ceramic Fig. 4. Comparison of the I factor effect over EW for the different ceramic
materials. materials.
 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038 1037

Fig. 5. Comparison of the ti factor effect over EW for the different Fig. 7. Comparison of the I factor effect over MRR for the different
ceramic materials. ceramic materials.

As shown in Fig. 7, the MRR variable increases when the

logical to expect, as an increase in the pulse energy (in this
intensity factor increases, in all the cases under considera-
case through an increase in pulse time) is usually associated
tion. However, in the case of boron carbide, this tendency to
with a decrease in electrode wear. On the contrary, in the
increase reaches a peak after which it begins to decrease with
cases of both silicon carbide and tungsten carbide, for the
the increase in intensity. This tendency of the MRR variable
considered work interval, the wear value tends to increase
to increase with the design factor of intensity is what would
when the pulse time factor also increases.
be expected, a priori, as the quantity of removed material is
Fig. 6 shows a comparative graph of the effect of duty
proportional to the size or area of the electrical pulse used.
cycle over EW for the three ceramic materials which have
On the other hand, as can be seen in Fig. 7, this tendency
been considered in this work.
to increase with respect to the intensity factor is much more
In the cases of boron carbide and silicon carbide, the elec-
obvious for the cases of both silicon carbide and tungsten
trode wear value tends to increase slightly when the duty
carbide.
cycle factor increases. Meanwhile, in the case of tungsten
Fig. 8 shows a comparative graph of the effect of the
carbide, EW increases slightly up to a maximum value, sit-
pulse time factor over MRR for the different ceramic ma-
uated around the central value of duty cycle (η = 0.5), after
terials. In the cases of silicon carbide and tungsten car-
which it tends to decrease with the increase in the previous
bide, the value of MRR tends to decrease when there is
design factor. In practice, the tendency which would be ex-
an increase in the value of the pulse time factor, which
pected, based on the experience gained from other types of
does not coincide with what would be expected a priori.
materials, is that of a decrease in wear with the decrease in
In practice, as was commented in the earlier case, the in-
pause time, which is equivalent to increasing the duty cycle
crease in the quantity of pulse energy, in this case through
factor, if the pulse time factor remains constant. Neverthe-
an increase in pulse time, tends to increase the value of
less, as has been previously seen, the main effect of the duty
MRR, although it always reaches a point where it starts
cycle factor does not turn out to be statistically significant
to decrease even though the pulse time value continues to
for any of the ceramic materials studied.
increase.
On the other hand, in the case of boron carbide, the MRR
4.3. Comparative analysis of the material removal rate value tends to decrease with pulse time down to a mini-
MRR mum value, around its central value, after which MRR tends
to increase with this factor. However, in the case of this
Fig. 7 shows the main effect of the intensity factor over ceramic material, the main effect of pulse time does not
the MRR variable, for the different ceramic materials con- turn out to be significant, for the confidence level under
sidered. consideration.

Fig. 6. Comparison of the η factor effect over EW for the different ceramic Fig. 8. Comparison of the ti factor effect over MRR for the different
materials. ceramic materials.
1038 I. Puertas, C.J. Luis / Journal of Materials Processing Technology 153–154 (2004) 1033–1038
Fig. 9. Comparison of the η factor effect over MRR for the different
ceramic materials.
Fig. 9 shows a comparative graph of the effect of duty
cycle over MRR for the three ceramic materials studied.
As shown in Fig. 9, the value of material removal rate
tends, in all the ceramic materials which were studied, to
increase when duty cycle has also been increased. This co-
incides with what would be expected in practice, based on
the experience acquired in the field of EDM for other ma-
terials, as, when pause time is reduced, which is equivalent
to increasing duty cycle, the MRR value tends to increase.
Furthermore, as can be seen in the previous Fig. 9, this ten-
dency for material removal rate to increase with duty cycle
is much more pronounced in the case of boron carbide than
in the case of the other two remaining ceramic materials.
5. Conclusions
The interest in the study of die-sinking EDM when ma-
chining conductive ceramics is a consequence of the diverse
problems brought about by the machining of these materials
by other manufacturing processes such as laser machining,
abrasive jet machining, ultrasonic machining and, even, di-
amond wheel grinding, among others.
It has been found that surface roughness increases when
intensity increases, for the cases of silicon carbide and
tungsten carbide. Conversely, in the case of boron carbide,
roughness tends to decrease with an increase in intensity.
Accordingly, it has been shown that an increase in pulse
time produces an increase in surface roughness. Further-
more, the fact of increasing duty cycle produces a worsening
in surface roughness, especially in silicon carbide. On the
other hand, in the case of boron carbide, just the opposite
behaviour has been observed.
With respect to electrode wear, in the case of boron car-
bide, it has been observed that it increases when intensity
also increases. On the contrary, in silicon carbide and tung-
sten carbide, it has been observed that the wear value de-
creases with the increase in intensity until reaching a min-
imum value. Furthermore, the electrode wear tends to de-
crease with the increase in pulse time in the case of boron
carbide. On the other hand, in the cases of silicon carbide
and tungsten carbide, just the opposite behaviour was ob-
served. Finally, it has been observed that EW tends to in-
crease when duty cycle is increased in the cases of boron
carbide and silicon carbide, whilst in the case of tungsten
carbide, it increases up to a maximum value after which it
decreases.
With regard to material removal rate, it has been con-
firmed that in all cases this increases when intensity in-
creases, although, in the case of boron carbide, this tendency
to grow reaches a maximum value after which it starts to
decrease. Furthermore, the fact of increasing pulse time
produces a decrease in material removal rate, in the cases
of silicon carbide and tungsten carbide. In the case of boron
carbide, it decreases with pulse time down to a minimum
value, after which it tends to increase. On the other hand,
it has been observed that material removal rate tends to
increase when duty cycle is increased for all the cases.
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