Scholarlink

<p>This study focuses on optimizing the microelectric-discharge milling (µEDM) process for fabricating microchannels in 3D-printed composites of onyx and carbon fiber, using gray relational analysis (GRA) and Harris hawk optimization (HHO). The composite specimens were micromachined via µEDM with tool electrodes of varying geometries—circular, triangular, and rectangular—crafted using wire electrical discharge grinding (WEDG). Key input parameters, including tool rotation (200, 600, and 100&#xa0;RPM), tool geometry (circular, rectangular, and triangular), voltage (100, 150, and 200&#xa0;V), and capacitance (33, 100, and 1000&#xa0;pF), were selected to minimize machining time and dimensional deviation. A hybrid GRA-HHO technique determined the optimal configuration, revealing the triangular tool as superior due to its enhanced erosion rate and effective debris removal. Optimal input conditions of 1000&#xa0;RPM, 200&#xa0;V, and 1000 pF capacitance resulted in the lowest machining time (89.3&#xa0;min) and dimensional deviation (20.5&#xa0;μm). Compared to Taguchi, the hybrid GRA-HHO optimization approach yielded an 18.81% reduction in machining time and a 6.39% improvement in dimensional accuracy. Morphological analyses of the machined surfaces validated that the triangular tool minimized overcutting and produced uniform microchannels. This approach offers valuable insights into the micromachining of 3D-printed composites, especially for applications in the automotive and aerospace sectors where precision and efficiency are critical.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Optimizing Electric-Discharge Milling for Microchannel Fabrication in 3D-Printed Composites Using Harris Hawk Optimization and Wire Electric-Discharge Ground Tools

  • 期刊论文

  • 发表日期：

    2025年9月29日

查看全文
  • Ankit Dhar Dubey,
  • Omkar Raj Aryan,
  • Satish Chaurasia,
  • Kishore Debnath,
  • Md Irfanul Haque Siddiqui,
  • Intesaaf Ashraf

摘要

This study focuses on optimizing the microelectric-discharge milling (µEDM) process for fabricating microchannels in 3D-printed composites of onyx and carbon fiber, using gray relational analysis (GRA) and Harris hawk optimization (HHO). The composite specimens were micromachined via µEDM with tool electrodes of varying geometries—circular, triangular, and rectangular—crafted using wire electrical discharge grinding (WEDG). Key input parameters, including tool rotation (200, 600, and 100 RPM), tool geometry (circular, rectangular, and triangular), voltage (100, 150, and 200 V), and capacitance (33, 100, and 1000 pF), were selected to minimize machining time and dimensional deviation. A hybrid GRA-HHO technique determined the optimal configuration, revealing the triangular tool as superior due to its enhanced erosion rate and effective debris removal. Optimal input conditions of 1000 RPM, 200 V, and 1000 pF capacitance resulted in the lowest machining time (89.3 min) and dimensional deviation (20.5 μm). Compared to Taguchi, the hybrid GRA-HHO optimization approach yielded an 18.81% reduction in machining time and a 6.39% improvement in dimensional accuracy. Morphological analyses of the machined surfaces validated that the triangular tool minimized overcutting and produced uniform microchannels. This approach offers valuable insights into the micromachining of 3D-printed composites, especially for applications in the automotive and aerospace sectors where precision and efficiency are critical.