Professional Documents
Culture Documents
Chapter 4
MACHINING OF CERAMICS
Introduction:
A ceramic is an inorganic, non-metallic solid prepared by the action of
heat and subsequent cooling. Ceramic materials may have a crystalline or
partly crystalline structure, or may be amorphous (e.g., a glass). Because most
common ceramics are crystalline, the definition of ceramic is often restricted to
inorganic crystalline materials, as opposed to the noncrystalline glasses, a
distinction followed here.
The word "ceramic" comes from the Greek word (keramikos) "of
pottery" or "for pottery" (keramos) "potter's clay, tile and pottery".
Page 1
Machining of ceramics
2) Non-crystalline ceramics:
Non-crystalline ceramics, being glass, tend to be formed from
melts. The glass is shaped when either fully molten, by casting, or when
in a state of toffee-like viscosity, by methods such as blowing into a
mould. If later heat treatments cause this glass to become partly
crystalline, the resulting material is known as a glass-ceramic, widely
used as cook-top and also as a glass composite material for nuclear waste
disposal.
fibre
reinforced,
Page 2
Machining of ceramics
Properties of Ceramics:
Ceramics have some attractive properties compared to metals and
polymers, which make them useful for specific applications. Their physical
properties have been utilized for many applications. In other applications their
mechanical properties are important.
The most important advantageous features of ceramic materials are:
1) Physical properties:
Physical properties means the behaviour of materials in response to
physical forces other than mechanical, such as; Volumetric, thermal,
electric and electrochemical properties.
Most Ceramics are lighter than metals but heavier than polymers.
Most ceramics have a higher melting point than most metals as it is
that some ceramics such as China can with stand high temperatures
to about 1200 degrees centigrade.
Ceramics also has lower Electrical and Thermal Conductivity than
most metals but the range of value is greater in ceramics permitting
some ceramics to be used as insulators, for example Porcelain
insulators and others as conductors like Lithium-ion conducting
glass-ceramics and oxide ceramics.
Advanced Material Removal Processes
Page 3
Machining of ceramics
2) Mechanical properties:
Mechanical properties are important in structural and building
materials as well as textile fabrics. They include the properties used to
describe the strength of materials such as: elasticity / plasticity, tensile
strength, compressive strength, shear strength, fracture toughness &
ductility (low in brittle materials), and indentation hardness.
Ceramic materials are usually ionic or covalent bonded materials,
and can be crystalline or amorphous. A material held together by either
type of bond will tend to fracture before any plastic deformation takes
place, which results in poor toughness in these materials. Additionally,
because these materials tend to be porous, the pores and other
microscopic imperfections act as stress concentrators, decreasing the
toughness further, and reducing the tensile strength. These combine to
give catastrophic failures, as opposed to the normally much more gentle
failure modes of metals.
Brittleness means that failure occurs without prior measurable
plastic deformation. This is due to the strong atomic bonding of ceramics,
which lead to high stresses for the motion of dislocations. Thus, failure
can start from small flaws before plastic deformation is possible. This fact
can also be expressed in low resistance against crack extension, which is
characterised by the fracture toughness. The absence of local plastic
deformation leads to failure at locations of high local stresses, e.g. at
notches, at contacts between different material or during thermal shock.
In metals these strain controlled local stresses lead to small plastic strains.
Page 4
Machining of ceramics
3) Electrical properties:
Semiconductors:Some ceramics are semiconductors. Most of these are
transition metal oxides that are II-VI semiconductors, such as zinc
oxide.
While there are prospects of mass-producing blue LEDs from
zinc oxide, ceramicists are most interested in the electrical properties
that show grain boundary effects.
One of the most widely used of these is the varistor. These are
devices that exhibit the property that resistance drops sharply at a
certain threshold voltage. This makes them ideal for surgeprotection applications; as there is control over the threshold voltage
and energy tolerance, they find use in all sorts of applications. The
best demonstration of their ability can be found in electrical
substations, where they are employed to protect the infrastructure
from lightning strikes. They have rapid response, are low
Advanced Material Removal Processes
Page 5
Machining of ceramics
Page 6
Machining of ceramics
Thus, there is an increasing need in the military sector for highstrength, robust materials which have the capability to transmit light
(electromagnetic waves) in the visible (0.4 0.7 micrometres) and midinfrared (1 5 micrometres) regions of the spectrum. These materials are
needed for applications requiring transparent armour, including nextgeneration high-speed missiles and pods, as well as protection against
improvised explosive devices (IED).
In the 1960s, scientists at General Electric (GE) discovered that
under the right manufacturing conditions, some ceramics, especially
aluminium oxide (alumina), could be made translucent. During the past
two decades, additional types of transparent ceramics have been
developed for applications such as nose cones for heat-seeking missiles,
windows for fighter aircraft, and scintillation counters for computed
tomography scanners.
Applications of Ceramics:
Knife blades: the blade of a ceramic knife will stay sharp for much
longer than that of a steel knife, although it is more brittle and can snap
from a fall onto a hard surface.
Ceramic brake disks for vehicles are resistant to abrasion at high
temperatures.
Advanced composite ceramic and metal matrices have been designed
for most modern armoured fighting vehicles because they offer superior
penetrating resistance against shaped charges (such as HEAT rounds)
and kinetic energy penetrators.
Ceramics such as alumina and boron carbide have been used in ballistic
armoured vests to repel large-calibre rifle fire. Such plates are known
commonly as small arms protective inserts, or SAPIs. Similar material
is used to protect the cockpits of some military airplanes, because of the
low weight of the material.
Ceramics can be used in place of steel for ball bearings. Their higher
hardness means they are much less susceptible to wear and typically last
for triple the lifetime of a steel part. Two drawbacks to ceramic bearings
are a significantly higher cost and susceptibility to damage under shock
loads.
Advanced Material Removal Processes
Page 7
Machining of ceramics
Recent advances have been made in ceramics which include bioceramics, such as dental implants and synthetic bones. Hydroxyapatite,
the natural mineral component of bone, has been made synthetically from
a number of biological and chemical sources and can be formed into
ceramic materials. Orthopaedic implants coated with these materials bond
readily to bone and other tissues in the body without rejection or
inflammatory reactions
Machining Techniques:
Ceramics are manufactured by compacting powder to a body which is
then sintered at high temperatures. The geometry, production volume and
characteristic requirements for the component govern the choice of
manufacturing process.
Ultrasonic machining:
1. Introduction:
Ultrasonic machining is a non-traditional machining process. USM
is grouped under the mechanical group NTM processes. Fig. 4.5 briefly
depicts the USM process.
Force, F
Vibration frequency f~ 19 - 25 kHz
Amplitude, a ~ 10 50 m
Horn
Slurry of abrasive
and water
Tool
Work
Page 8
Machining of ceramics
Page 9
Machining of ceramics
Page 10
Machining of ceramics
a0
MRR
MRR, Q
a0
MRR, Q
MRR
dg
B4C
MRR, Q
Al2O3
MRR
Page 11
Machining of ceramics
4. Machine:
The basic mechanical structure of an USM is very similar to a drill
press. However, it has additional features to carry out USM of brittle
work material. The workpiece is mounted on a vice, which can be located
at the desired position under the tool using a 2 axis table. The table can
further be lowered or raised to accommodate work of different thickness.
The typical elements of an USM are (Fig. 4.7)
Feed motion
Transducer
Horn
Workpiece
Slurry pump
Slurry tank
Page 12
Machining of ceramics
Signal
generator
Vibration
propagation
Horn
Tool
Page 13
Machining of ceramics
Exponential
Tapered
Stepped
Page 14
Machining of ceramics
changing the setting of the output control of the power supply, the
amplitude of the ultrasonic vibration can be adjusted. The spindle speed
(measured in revolutions per minute [rpm]) is programmable using the
CNC controller for speeds up to 8000 rpm.
A variety of tool shapes are used for rotary ultrasonic machining,
and ceramic and technical glass machining applications typically use
either a diamond-impregnated or electroplated tool. Diamondimpregnated tools are more durable, but electroplated tools are less
expensive, so the selection depends on the particular application.
One of the major differences between USM and RUM equipment
is that USM uses a soft tool, such as stainless steel, brass or mild steel,
and slurry loaded with hard abrasive particles, while in RUM the hard
abrasive particles are diamond and are bonded on the tools. Another
major difference is that the RUM tool rotates and vibrates
simultaneously, while the USM tool only vibrates. These differences
enable RUM to provide both speed and accuracy advantages in ceramic
and glass machining operations.
Page 15
Machining of ceramics
Figure-4.10: In ultrasonic machining, the tool, which is shaped conversely to the desired hole
or cavity, oscillates at high frequency, typically 20 kHz, and is fed into the workpiece by a
constant force.
Page 16
Machining of ceramics
Figure-4.11: In rotary ultrasonic machining, a rotating core drill with metal-bonded diamond
abrasives is ultrasonically vibrated in the axial direction while the spindle is fed toward the
workpiece at a constant pressure.
Page 17
Machining of ceramics
Page 18
Machining of ceramics
Grinding of ceramics:
Grinding is used in machining of Ceramics in the sintered state.
Grinding operation involves a rotating abrasive wheel removing the
material from the surface of the workpiece.
The grinding zone is continuously flushed with a fluid coolant,
which cools the grinding zone, lubricates the contact between the wheel
and the part surfaces, removes the micro-chips (debris) produced in the
grinding process.
Resin-bond wheels with either synthetic or natural diamond of
different grit size pressed at different concentrations in polymer (resin)
matrices are commonly used for grinding ceramics.
Electrolytic in-process dressing (ELID) technique of dressing
metal-bonded grinding wheels is used for fine (Nano) finishes grinding.
The Material Removal Rate (MRR) of grinding ceramics is
maximum 9.832 mm3/min.
Page 19
Machining of ceramics
Drilling
Cutting
Scribing and marking
Page 20
Machining of ceramics
Sintering:
Sintering is a method for creating objects from powders,
including metal and ceramic powders. It is based on atomic diffusion.
Diffusion occurs in any material above absolute zero, but it occurs much
faster at higher temperatures. In most sintering processes, the powdered
material is held in a mould and then heated to a temperature below the
melting point. The atoms in the powder particles diffuse across the
boundaries of the particles, fusing the particles together and creating one
solid piece. Because the sintering temperature does not have to reach the
melting point of the material, sintering is often chosen as the shaping
process for materials with extremely high melting points such as
tungsten and molybdenum.
Sintering is traditionally used for manufacturing ceramic objects
but finds applications in almost all fields of industry. The study of
sintering and of powder-related processes is known as powder
metallurgy. A simple, intuitive example of sintering can be observed
when ice cubes in a glass of water adhere to each other.
In certain moulding processes a relatively large amount of
temporary organic binder is used, which needs to be burnt out in a
separate step. Sintering is then carried out in air. We have furnaces for
sintering in air up to 1800C, or inert graphite furnaces with a maximum
temperature of 2300C.
Ceramic sintering:
Sintering is part of the firing process used in the manufacture of
pottery and other ceramic objects. These objects are made from
substances such as glass, alumina, zirconia, silica, magnesia, lime,
beryllium oxide and ferric oxide. Some ceramic raw materials have a
lower affinity for water and a lower plasticity index than clay, requiring
organic additives in the stages before sintering. The general procedure of
creating ceramic objects via sintering of powders includes:
Mixing water, binder, deflocculant, and unfired ceramic powder to
form a slurry;
Advanced Material Removal Processes
Page 21
Machining of ceramics
Page 22
Machining of ceramics
vessel. The pressurizing gas most widely used is argon. An inert gas is
used, so that the material does not chemically react. The chamber is
heated, causing the pressure inside the vessel to increase. Many systems
use associated gas pumping to achieve the necessary pressure level.
Pressure is applied to the material from all directions (hence the term
"isostatic").
For processing castings, metal powders can also be turned to
compact solids by this method; the inert gas is applied between 50.7 MPa
and 310 MPa, with 100 MPa being most common. Process soak
temperatures range from 482 C for aluminium castings to 1,320 C for
nickel-based superalloys. When castings are treated with HIP, the
simultaneous application of heat and pressure eliminates internal voids
and micro-porosity through a combination of plastic deformation,
creep, and diffusion bonding; this process improves fatigue resistance of
the component. Primary applications are the reduction of microshrinkage, the consolidation of powder metals, ceramic composites and
metal cladding. Hot isostatic pressing is also used as part of a sintering
(powder metallurgy) process and for fabrication of metal matrix
composites.
Enhanced product properties:The ability to manufacture HIP products with irregular shapes and
complex geometry offers several advantages over castings, forgings and
fabricated materials, both in terms of design flexibility and material
properties.
The fine microstructure and isostatic pressure with which the HIP
products are processed result in isotropic mechanical properties, in other
words, properties that are equal in all directions. The isotropic properties
can contribute to, for example, lighter constructions.
Main advantages with products produced by hot isostatic pressing:
Page 23
Machining of ceramics
Powder Metallurgy:
Powder metal consolidation via HIP is used to produce near net
shape components faster, with reduced weight and less machining than
traditional castings and forgings.
Page 24
Machining of ceramics
Finishing Process:
Ceramic glaze:
Glaze is a layer or coating of a vitreous substance which has been
fused to a ceramic object through firing. Glaze can serve to color,
decorate, strengthen or waterproof an item.
Use:Glazing is important for earthenware vessels as otherwise they
would be unsuitable for holding liquids due to porosity. Glaze is also
used on stoneware and porcelain. In addition to the functional aspect of
glazes, they can form a variety of surface finishes, including degrees of
gloss and matte and color. Glazes may also enhance an underlying design
or texture which may be either the unmodified texture of the underlying
body, or an inscribed, carved or painted design.
Glaze is used on building materials. The Iron Pagoda, built in
1049 in Kaifeng, China, of glazed bricks is an example.
Composition:Ceramic glaze raw materials generally include silica, which will be
the main glass former. Various metal oxides, such as sodium, potassium
and calcium, act as a flux to lower the melting temperature. Alumina,
often derived from clay, stiffens the molten glaze to prevent it from
running off the piece. Colorants, such as iron oxide, copper carbonate
or cobalt carbonate, and sometimes opacifiers such as tin oxide or
zirconium oxide, are used to modify the visual appearance of the fired
glaze.
Process:Glaze may be applied by dry dusting a dry mixture over the surface
of the clay body or by inserting salt or soda into the kiln at high
temperatures to create an atmosphere rich in sodium vapor that interacts
with the aluminium and silica oxides in the body to form and deposit
glass, producing what is known as salt glaze pottery. Most commonly,
glazes in aqueous suspension of various powdered minerals and metal
oxides are applied by dipping pieces directly into the glaze. Other
Advanced Material Removal Processes
Page 25
Machining of ceramics
techniques include pouring the glaze over the piece, spraying it onto the
piece with an airbrush or similar tool, or applying it directly with a brush
or other tool.
To prevent the glazed article from sticking to the kiln during firing
either a small part of the item is left unglazed or supported on small
refractory supports called kiln spurs which are removed and discarded
after the firing. Small marks left by these spurs are sometimes visible on
finished ware.
Decoration applied under the glaze on pottery is generally referred
to as underglaze. Underglazes are applied to the surface of the pottery,
which can be either raw, "greenware", or "biscuit" fired (an initial firing
of some articles before the glazing and re-firing). A wet glazeusually
transparentis applied over the decoration. The pigment fuses with the
glaze, and appears to be underneath a layer of clear glaze. An example of
underglaze decoration is the well-known "blue and white" porcelain
famously produced in England, The Netherlands, China and Japan.
The striking blue color is achieved by using cobalt in the form of either
cobalt oxide or cobalt carbonate, both of which are still commonly used.
Decoration applied on top of a layer of glaze is referred to as
overglaze. Overglaze methods include applying one or more layers or
coats of glaze on a piece of pottery or by applying a non-glaze substance
such as enamel or metals (i.e., gold leaf) over the glaze.
Overglaze colours are low-temperature glazes that give ceramics a
more decorative, glassy look. A piece is fired first, overglaze is applied,
and it is fired again. Once the piece is fired and comes out of the kiln, its
texture becomes smoother because of the glaze.
Page 26