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Glass fibers are popular over traditional materials as they have a greater strength with light weight providing better dimensional stability and flexibility in improving designs and applications. Milling Electrochemical Spark Micromachining (M-ECSMM) is an emerging hybrid micromachining process that creates microchannels on brittle non-conducting materials. In the present work, microchannels were made on an E-glass fiber-reinforced polymer (E-GFRP) composite using M-ECSMM. Experiments are carried out using CCD-based DOE considering having voltage (V) and speed (N, rpm) as input parameters and the rate at which material is removed as MRR, tool wear rate (TWR), and average roughness (Ra) as response parameters. The multi-response optimization was carried out using desirability function analysis (DFA), and the optimal solution obtained using DFA at 140 V and 14.4 rpm, the predicted value for MRR of 26.6765 mg/min, TWR as 13.7432 mg/min, and Ra as 10.5063.

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Face-Centered CCD-Based RSM Modeling and Optimization of Parameters for Milling Electrochemical Spark Micromachining of E-Glass Fiber Composites

  • 会议论文

  • 发表日期：

    2026年

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  • Kriti Sahai,
  • Audhesh Narayan

摘要

Glass fibers are popular over traditional materials as they have a greater strength with light weight providing better dimensional stability and flexibility in improving designs and applications. Milling Electrochemical Spark Micromachining (M-ECSMM) is an emerging hybrid micromachining process that creates microchannels on brittle non-conducting materials. In the present work, microchannels were made on an E-glass fiber-reinforced polymer (E-GFRP) composite using M-ECSMM. Experiments are carried out using CCD-based DOE considering having voltage (V) and speed (N, rpm) as input parameters and the rate at which material is removed as MRR, tool wear rate (TWR), and average roughness (Ra) as response parameters. The multi-response optimization was carried out using desirability function analysis (DFA), and the optimal solution obtained using DFA at 140 V and 14.4 rpm, the predicted value for MRR of 26.6765 mg/min, TWR as 13.7432 mg/min, and Ra as 10.5063.