Design and Analysis of CFRP Drilling by Electrical Discharge Machining

Roldán-Jiménez, Luis; Bañon, Fermin; Puerta, Ana Pilar Valerga; Fernández-Vidal, S.R.

doi:10.3390/polym14071340

Cited by 16 publications

(5 citation statements)

References 37 publications

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“…According to the literature, UVAM can facilitate chip breaking, reduce cutting force, extend tool life extension and suppress delamination / burr in machining of CF/epoxy [128][129][130], metals [131,132] and their stacked structures [133][134][135]. On the other hand, EDM shows minimized geometric deviations and improved surface quality in machining of CF/epoxy [136,137]. It would be of interest to carry out new studies deploying these techniques in the context of FRTP machining and learn whether these technologies would outperform other machining techniques.…”

Section: Laser Beam Machining (Lbm)mentioning

confidence: 99%

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Luo

Catalanotti

et al. 2023

Preprint

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Fibre reinforced thermoplastic polymer (FRTP) composites have been used for a wide range of engineering applications (e.g. in transport, construction, energy, etc) due to their excellent mechanical properties and ease of repair and recycling. In recent years, FRTP is increasingly deployed as an alternative to conventional thermoset carbon fibre reinforced epoxy (CF/epoxy) composites, for the purpose of reducing the carbon footprint and contributing to a sustainable manufacturing agenda. Machining of FRTP remains an indispensable process to achieve rapid parts assembly whilst meeting stringent geometric tolerances. However, due to the heterogeneous structure and high thermal sensitivity of FRTP, a range of machining-induced damages (such as matrix smearing, thermal degradation, delamination, burr and surface cavity) often occur, leading to concerns on machined parts quality and reliability. To date, composite machining studies have been mostly focused on conventional thermoset CF/epoxy and there is a lack of an up-to-date, in-depth review of the latest advancement concerning the machining of FRTP. This paper provides a state-of-the-art overview on the recent developments in FRTP machining over the past decade, with a particular emphasis on machining characteristics, damage mechanisms as well as the challenges facing such manufacturing process. The purpose is to present the composite manufacturing community with a timely update, which may guide and inspire further research and development for future FRTP manufacturing.

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Section: Laser Beam Machining (Lbm)mentioning

confidence: 99%

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Luo

Catalanotti

et al. 2023

Preprint

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“…Ming et al [26] conducted abrasive waterjet trials on CFRP, noting a loss of dimensional accuracy near the jet exit due to reduced cutting ability stemming from kinetic energy loss. In contrast, Electrical Discharge Machining (EDM) has received limited attention in the context of CFRP machining, primarily due to the inherent challenge of achieving electrical conductivity between the electrode and the non-conductive matrix [27]. However, in more recent research, die-sink Electrical Discharge Machining (EDM) has been thoroughly examined and its feasibility in both macro and micro drilling of CFRP has been con rmed.…”

Section: Introductionmentioning

confidence: 99%

The Machining Characteristics of Drilling Multidirectional CFRP Using Wire Electrical Discharge Machining

Hasan,

Abdallah

2023

Preprint

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This paper examines the feasibility of wire electrical discharge machining (WEDM) on drilling multidirectional carbon-fibre-reinforced plastic (CFRP) composite laminates using high-performance wire electrodes. A full factorial experimental array of 8 (23) tests was employed to evaluate the effect of varying the machining parameters including pulse-on time (0.6 and 0.9 µs), pulse-off time (4 and 6 µs), and wire type (Compeed and Topas Plus D) on the material removal rate (MRR), top and bottom delamination factor (DFT and DFB) and surface integrity. The results revealed that the MRR varied between 1.35 and 2.9 mm3/min and increased by high pulse on time and low pulse off time as a result of the higher discharge energy generated. Despite, none of the parameters having a significant effect on MRR, the pulse-off time was found to have the largest percentage contribution ratio (PCR), with a value of 71.8%. The Topas Plus D wire exhibited a higher MRR (up to 21%) under the same cutting conditions compared to the Compeed wire electrode. Regarding the delamination, the top and bottom factors ranged from 1.06 to 1.20 and 1.08 to 1.25 respectively. The pulse-on time and its interaction with the pulse-off time had the highest PCR on DFT, with values of 26.86% and 38.21%, respectively, according to ANOVA, which showed that none of the parameters had a significant impact on delamination. Optical micrographs of the workpiece revealed the presence of defects in terms of poor hole quality/roundness error, frayed fibres, excessive delamination, and adhered debris (including wire electrode contaminants) on both the top and bottom surfaces. These defects tended to be more noticeable in experiments using the Compeed wire electrode, probably as a result of the higher discharge energies.

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“…First is the cutting wear zone generated through the cutting action of the abrasives impinging on the material surface at acute angles [13,14]. The second deformation wear zone is produced when the abrasives strike the material surface at obtuse impact angles [15]. Smaller impact angles produce smooth cutting surfaces, while large impact angles produce a distorted and rough machined surface [16].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Process Parameters to Minimize the Surface Roughness of Abrasive Water Jet Machined Jute/Epoxy Composites for Different Fiber Inclinations

Murthy,

Makki,

Potti

et al. 2023

J. Compos. Sci.

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Composites materials like jute/epoxy exhibit high hardness and are considered as difficult-to-machine materials. As a result, alternatives to conventional machining become essential to post-process the composites. Accordingly, due to its non-thermal nature, abrasive water jet machining has recently come to be seen as one of the most promising machining methods for composite materials. In the current study, the impact of machining parameters such as traverse speed (TS), standoff distance (SOD) and abrasive mass flow rate (MFR) on machined surface roughness (Ra) has been investigated. In addition, the optimum combination of process parameters to machine a jute fiber-reinforced polymer composite with minimum Ra is predicted. The experimental results are analyzed using Taguchi and Response Surface Methodology (RSM) approaches to determine the optimum set of process parameters to achieve the lowest roughness values. Without making any changes in the machining conditions, the optimum set of values is determined for two conditions by reinforcing the fiber with 45° inclination and 90° inclination. The results reflect the different optimum combinations for each fiber inclination. For 45° fiber inclination, to achieve the minimum Ra value, the predicted combination is TS = 30 mm/min, SOD = 2 mm and MFR = 0.35 kg/min. When the fiber inclination is 90°, the predicted optimum combination is TS = 25 mm/min, SOD = 2 mm, and MFR = 0.35 kg/min. It is evident from the results that the optimum combination will be changed according to the machining conditions as well as material properties. The results confirm the effect of fiber orientation on surface roughness. The specimen with 45° fiber inclination produces a lower Ra with an average of 4.116 µm, and the specimen with 90° fiber inclination generates a higher Ra with an average of 4.961 µm.

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Design and Analysis of CFRP Drilling by Electrical Discharge Machining

Cited by 16 publications

References 37 publications

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

The Machining Characteristics of Drilling Multidirectional CFRP Using Wire Electrical Discharge Machining

Optimization of Process Parameters to Minimize the Surface Roughness of Abrasive Water Jet Machined Jute/Epoxy Composites for Different Fiber Inclinations

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