Electrical discharge drilling of carbon fibre reinforced composite materials

Gourgouletis, Konstantinos; Vaxevanidis, Nikolaos M.; Galanis, Nikolaos I.; Manolakos, D.E.

doi:10.1504/ijmmm.2011.042190

Cited by 8 publications

(6 citation statements)

References 18 publications

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“…It was suggested that the proper selection of process parameters would lead to increased MRR and decreased TWR. Gourgouletis et al studied the feasibility of using die sinking EDM on CFRP. Blind holes were drilled using a copper electrode.…”

Section: Literature Surveymentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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This article presents micro electrical discharge machining (μEDM) of carbon fiber‐reinforced plastics (CFRP) with rotating tool electrode and assisting electrode (AE). The experimental investigation majorly focused on establishing the mechanisms of material removal and surface integrity of the machined blind holes. Taguchi and regression analysis were carried out to assess the material removal rate (MRR). Analysis of variance (ANOVA) was applied to understand the significance of input parameters and their contribution toward achieving maximum MRR. The surface integrity of the machined hole and damage modes of composite constituents were also examined through micrographic images. The experiments were carried out varying the voltage, pulse duration, and tool speed at three levels. The investigations showed that μEDM process can be applied for fabricating micro holes in CFRP if assisting electrode (AE) is used to initiate the spark. From the analysis of variance (ANOVA), it was observed that the percentage contribution of voltage, pulse duration, and tool rotational speed on MRR are 75.09, 5.20, and 16.09%, respectively. The optimal condition for the highest MRR was found to be V3/T1/S3 (voltage of 170 V, pulse duration of 10 μs, and tool speed of 800 rpm). The calculated value of MRR (341,264.94 μm3/s) at the optimum level of input parameters was found to be close to the experimental MRR (340,727 μm3/s). The percentage error between the experimental and calculated value of MRR at the optimum level is very low as 0.15%. This indicates that the developed statistical model is quite significant in predicting MRR during μEDM of CFRP. POLYM. COMPOS., 40:4033–4041, 2019. © 2019 Society of Plastics Engineers

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Section: Literature Surveymentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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“…It was found that discharge current had the highest influence on the surface roughness of the machined material. Gourgouletis et al 20 confirmed the feasibility of using EDM for drilling CFRP composites. Lau et al 6 stated that the copper electrode performs better than the graphite electrode in terms of electrode wear during EDM of CFRP composites.…”

Section: Introductionmentioning

confidence: 93%

Investigation on cutting of thin carbon fiber-reinforced polymer composite plate using sandwich electrode-assisted wire electrical-discharge machining

Dutta

Debnath

Sarma

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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This paper presents the experimental investigation on cutting of thin carbon fiber-reinforced polymer (CFRP) composite plate by wire electrical-discharge machining (WEDM) with the aid of sandwich assisting-electrodes. The difficulties such as incomplete cut and deviation in machining path during WEDM of CFRP were avoided by using metal plates (H13 steel) as assisting-electrodes. The spark initiation during WEDM of CFRP is difficult without exposing the carbon fiber as fibers are embedded into nonconductive polymer in CFRP. Thus, in this work, assisting-electrode was used to initiate the sparking without changing the surface integrity of the CFRP. The one-factor-at-a-time analysis was applied to study the effect of input parameters namely input current (2, 4, 6, 8, 10, and 12 A), pulse on time (10, 20, 30, 40, 50, and 60 µs), pulse off time (10, 20, 30, 40, 50, and 60 µs), and voltage (70 and 90 V) on the cutting time and the machined surface morphology. A decreasing trend was observed for cutting time with an increase in the current. Whereas, the cutting time was increased with an increase in the pulse off time. It was also observed that the cutting time initially increased with the pulse on time (10 to 30 µs) and then started decreasing with a further increase in the pulse on time (40 to 60 µs). The cutting time was significantly reduced at a higher level of voltage (90 V) when compared one-on-one with lower voltage level (70 V). In this study, microscopic analysis of the surface morphology was also extensively investigated which was not investigated earlier. The investigation showed damages such as breakage of carbon fibers, fiber-matrix debonding, and matrix cracking during WEDM of CFRP using sandwich assisting-electrode.

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“…Also, it has been shown that the high discharge current greatly influenced hole quality. Gourgouletis et al [40] explored the die-sinking EDM on CFRP material with the used copper tool. The response of the machining process (blind holes) was evaluated namely, MRR, tool wear rate (TWR) and surface integrity.…”

Section: Introductionmentioning

confidence: 99%

Micro electric discharge machining (μ-EDM) of polymer nanocomposites modified by graphene nanoplatelets/carbon using rotating electrode tool

Vishwakarma¹,

Verma²

2021

J. Micromech. Microeng.

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The micro-sized hole is highly required in biomedical, electronics, optical, aerospace components that are not feasible by the traditional machining process. This study highlights the precise micromachining on the polymer nanocomposites modified by graphene nanoplatelet (GNP) and carbon fiber. The electric discharge machining (EDM) of polymeric composites is too complicated due to its lower conductivity and abrasive nature. The little concentration of GNP in the epoxy matrix expands the machinability aspect of the polymers. The reinforcing conductive particle is used for the micro EDM (μEDM) of the laminate nanocomposites with a rotating tool electrode. The Taguchi concept-based orthogonal array was used to execute the machining test. The material removal rate (MRR) during the μEDM of the developed laminate nanocomposites was estimated using the sine cosine algorithm. The tests were conducted at three levels of process constraints: voltages, length of the pulses, and weight % of the GNP. The higher value of MRR is obtained at the optimal condition of voltage at three level, length of pulse two level, and weight % of GNP three level. The quality of the machined hole and the surface damages during the machining test were investigated by a field electron scanning electron microscope. The microscopy findings reveal that GNP addition significantly influences the nanocomposite micromachining.

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Electrical discharge drilling of carbon fibre reinforced composite materials

Cited by 8 publications

References 18 publications

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

Investigation on cutting of thin carbon fiber-reinforced polymer composite plate using sandwich electrode-assisted wire electrical-discharge machining

Micro electric discharge machining (μ-EDM) of polymer nanocomposites modified by graphene nanoplatelets/carbon using rotating electrode tool

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