Experimental Investigations into Electrochemical Spark Machining of Composites

Abstract

Reports have indicated the poor performance of the conventional type of cutting tools during machining of composites. In this paper electrochemical spark machining (ECSM) for the cutting and drilling of holes in the composites is being proposed. The feasibility of using ECSM for composites was first ascertained. Then, kevlar-fiber-epoxy and glass-fiber-epoxy composites as work material, copper as tool material, and an aqueous solution of NaCl as electrolyte were used. It has been concluded that the ECSM is a viable solution for cutting of Fiber Reinforced Plastics (FRP). For achieving desired accuracy, surface finish, and economics of the process, the machining parameters should be optimized.

The path towards delamination-free drilling of composite materials

“…The material removal rate also increases with the specific conductance of the electrolyte but decreases as the fiber volume fraction increases. The capacity to machine blind holes in Kelvar-epoxy composite material was demonstrated [113].…”

“…The glass-epoxy and aramid-epoxy laminates can be cut by ECSM [112][113][114]. The effects of voltage, electrolyte conductivity, fiber volume fraction and tool diameter on material removal rate, tool wear and overcut have been studied.…”

On the mechanism of material removal in electrochemical spark machining of quartz under different polarity conditions

“…Electrochemical spark machining (ECSM) is a newly developed hybrid process that combines both ECM and EDM (ECM + EDM → ECSM). It can be successfully used for machining electrically non-conductive advanced engineering materials (Withrich and Fascio, 2005;Kim et al, 2006;Tandon et al, 1990;Jain et al, 1990). However, it is not being used on the shop floor due to its limitations hence it requires in-depth 0924-0136/$ -see front matter © 2007 Elsevier B.V. All rights reserved.…”

A novel approach for removal of delaminated fibers of a reinforced composites using electrochemical discharge machining

“…This is in contrast with EDM and ECM which can be used for only conductive materials. Jain et al 17 identified the potential of ECSM process on composites. The authors successfully used ECSM process for drilling of Kevlar fiber epoxy and glass fiber epoxy composites.…”