Carbon fiber-reinforced polymer (CFRP) composites are highly valued in the automotive, aerospace, electronics, and sports industries for their diverse range of applications. However, owing to its anisotropic and abrasive behavior, the traditional techniques have become difficult to fabricate micro-holes in CFRP composite. These days, a novel hybrid technology called electrochemical discharge machining (ECDM) is widely utilized to manufacture these kinds of materials in order to reduce this problem. In this study, machined micro-holes produced by the ECDM method on CFRP composites are examined experimentally and statistically. The experiments were conducted using the L16 orthogonal array proposed by Taguchi. There are four input parameters divided into four levels: concentration of electrolyte, rotational speed of tool, tool travel rate, and duty cycle. The output responses were MRR and hole overcut. The concentration of electrolyte and duty cycle were the most critical parameters affecting both MRR and overcut. The selected parameters were optimized using a multi-response optimization technique based on TOPSIS-Entropy. The optimal parametric combination for output responses was found at 35%, 480 RPM, 1.0 mm/min, and 90%, respectively. SEM images revealed that some damaged surroundings, heat-affected cone, crater were present on the machined surfaces at high duty cycle and electrolyte concentration.

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Machining of CFRP Composites Using Electrochemical Discharge Machining Process

  • Santosh Kumar Yadav,
  • Abhishek Singh,
  • Kishore Debnath,
  • Nav Rattan,
  • Dinesh Kumar

摘要

Carbon fiber-reinforced polymer (CFRP) composites are highly valued in the automotive, aerospace, electronics, and sports industries for their diverse range of applications. However, owing to its anisotropic and abrasive behavior, the traditional techniques have become difficult to fabricate micro-holes in CFRP composite. These days, a novel hybrid technology called electrochemical discharge machining (ECDM) is widely utilized to manufacture these kinds of materials in order to reduce this problem. In this study, machined micro-holes produced by the ECDM method on CFRP composites are examined experimentally and statistically. The experiments were conducted using the L16 orthogonal array proposed by Taguchi. There are four input parameters divided into four levels: concentration of electrolyte, rotational speed of tool, tool travel rate, and duty cycle. The output responses were MRR and hole overcut. The concentration of electrolyte and duty cycle were the most critical parameters affecting both MRR and overcut. The selected parameters were optimized using a multi-response optimization technique based on TOPSIS-Entropy. The optimal parametric combination for output responses was found at 35%, 480 RPM, 1.0 mm/min, and 90%, respectively. SEM images revealed that some damaged surroundings, heat-affected cone, crater were present on the machined surfaces at high duty cycle and electrolyte concentration.