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 11 publications

(4 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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“…In the domain of conventional machining processes, the drilling and milling process were widely used for processing of CFRP though it remains less popular owing to delamination, tool wear and uncut fibers [ 4 , 5 ]. On the other hand, the Electrical Discharge Machining (EDM) has gained the interest of research fraternity for surface modification and micro-machining of CFRP [ 6 , 7 ]. Though, the application of EDM process was limited for CFRP composites due to its partial conductivity.…”

Section: Introductionmentioning

confidence: 99%

Multi Response Optimization of ECDM Process for Generating Micro Holes in CFRP Composite Using TOPSIS Methodology

Singh

Arora

et al. 2022

Polymers

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The applications of carbon fiber reinforced polymer composites (CFRPCs) in aerospace, automotive, electronics and lab-on-chip devices require precise machining processes. Over the past decade, there have been numerous attempts to machine CFRPCs using both traditional and unconventional machining techniques. However, because of their limitations, these methods have not gained widespread acceptance. In the present research investigation, Electrochemical Discharge Machining (ECDM) process has been employed to produce micro-holes on CFRPC. The experimental strategy was scheduled using L9 orthogonal array keeping applied voltage, electrolyte concentration and inter-electrode gap as input parameters. The material removal rate (MRR) and overcut were selected as output parameters. The technique for order preference by similarity to the ideal solution (TOPSIS) methodology was executed for multi-response optimization. The overcut and MRR of machined samples improved from 150 µm to 48 µm and 2.232 mg/min to 2.1267 mg/min correspondingly while using the optimum parametric settings of the TOPSIS approach. The shape of drilled micro-holes produced by the TOPSIS process is indicative of a machined surface of superior quality, with a reduction in the number of micro-cracks and a diameter that is uniform.

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Design and Analysis of CFRP Drilling by Electrical Discharge Machining

Cited by 11 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

Multi Response Optimization of ECDM Process for Generating Micro Holes in CFRP Composite Using TOPSIS Methodology

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