An experimental framework for micro-EDM texturing on ceramic injection moulds for improved feedstock flowability

Micro ceramic injection moulding is a commonly used replication method for mass production of ceramics parts of complex shapes with tight tolerance. However, improving the wear resistance of moulding surfaces as well as enhancing the injection feedstock flowability is a challenging task for ensuring the homogeneous productions. To resolve this challenge, micro-EDM based surface structuring of the STAVAX steel mould has been put forward in this paper. Conventionally, short and ultra-short pulsed laser micromachining are used for texturing. However, the beam based methods (lasers) have limited control on dimple shape and dimensions. Femto-second lasers have proven in demonstrating better dimensional control of textures but the processing speed becomes low. Furthermore, reflectivity issues on the curved and polished mould surfaces limit texturing performance. Therefore, micro-EDM is put forward as a tool-based texturing method to achieve better control over dimple shape and dimensions. A large amount, i.e. 2500, of micro-dimples were textured along the 100 mm spiral channel, which is used for the injection flowability test. Before machining, micro-EDM tool path planning along a spiral trajectory planning has been generated. The structured surface topology has been characterized together with a statistical analysis of the frontal tool wear. The spiral flow test has showed the effectiveness of applying micro-EDM in structuring the complex injection mould.

ISBN:978-0-9957751-9-0

Jaar van publicatie:2021

Toegankelijkheid:Embargoed