Application of conventional machining techniques for green ceramic compacts produced by powder reaction moulding.

Ng, S.H., 2005. Application of conventional machining techniques for green ceramic compacts produced by powder reaction moulding. PhD, Nottingham Trent University.

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The study of the green machining of a new ceramic material is important for the future development and application of that material, since this is a common manufacturing process in many industries. Following a previous research project at Nottingham Trent University that led to the development of a novel alumina/cyanoacrylate material produced by Powder Reaction Injection Moulding Engineering (PRIME), this research programme has been designed to investigate the application of conventional machining techniques for the green ceramic compacts.

In order to produce a high quality machinable novel green compact, experimental investigation of a number of processing parameters and conditions for producing the green compacts was undertaken. Various cyanoacrylates were investigated for their suitability as a binder for the alumina powder. A series of experiments have been performed to establish the effects of the relevant parameters, such as inhibition, initiation and mixing condition on product integrity and process efficiency, since the cyanoacrylate was an exceedingly reactive binder, which posed problems when mixing the feedstock. Para-toluene-sulphonic acid has been determined as an effective inhibitor, and caffeine as an effective initiator, for the alumina/cyanoacrylate feedstock.

The moulded green compacts were investigated to establish their machinibility using conventional machining operations: turning, milling and drilling. The green compacts could be machined exceptionally well using these conventional methods. The results indicated that the green compacts have adequate mechanical strength to withstand the shearing action produced by the tool during the machining operations.

In order to gain a better appreciation of how the material behaved during the machining processes, a finite element analysis (FEA) was used to simulate the machining of the alumina/cyanoacrylate compact. The turning of the green compact was simulated in 2D using DEFORM 2D.

The moulded and the machined alumina/cyanoacrylate compacts were then investigated to establish their debinding and sinterability using conventional thermal equipment.

The main thrust of this research was focused on green machining of the novel material, from both the practical and modelling viewpoints, to develop a detailed understanding of the nature of the processes involved.

Item Type: Thesis
Creators: Ng, S.H.
Date: 2005
ISBN: 9781369314069
Rights: This thesis has been supplied on condition that anyone who consults it is understood to recognise that its copyright rests with the author and that no information derived from it may be published without the author’s prior written consent.
Divisions: Schools > School of Science and Technology
Record created by: Jeremy Silvester
Date Added: 18 Sep 2020 09:16
Last Modified: 19 Jul 2023 10:55

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