Fabrication of micro holes in CFRP laminates using EDM

Kumar, Ravinder; Agrawal, Pramod Kumar; Singh, Inderdeep

doi:10.1016/j.jmapro.2018.01.011

Cited by 49 publications

(13 citation statements)

References 17 publications

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“…In recent years, precise machining of CFRP has become an area of paramount concern in the field of manufacturing. The use of precise micro holes in CFRP can be seen in vibration measurement in the field of fiber optics, temperature measurement, and detection of cracks and delamination . The research conducted in the area of micro electrical discharge machining (μEDM) of CFRP showed that no in‐depth study has been carried out in the context of making of microholes in CFRP by means of μEDM process.…”

Section: Introductionmentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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This article presents micro electrical discharge machining (μEDM) of carbon fiber‐reinforced plastics (CFRP) with rotating tool electrode and assisting electrode (AE). The experimental investigation majorly focused on establishing the mechanisms of material removal and surface integrity of the machined blind holes. Taguchi and regression analysis were carried out to assess the material removal rate (MRR). Analysis of variance (ANOVA) was applied to understand the significance of input parameters and their contribution toward achieving maximum MRR. The surface integrity of the machined hole and damage modes of composite constituents were also examined through micrographic images. The experiments were carried out varying the voltage, pulse duration, and tool speed at three levels. The investigations showed that μEDM process can be applied for fabricating micro holes in CFRP if assisting electrode (AE) is used to initiate the spark. From the analysis of variance (ANOVA), it was observed that the percentage contribution of voltage, pulse duration, and tool rotational speed on MRR are 75.09, 5.20, and 16.09%, respectively. The optimal condition for the highest MRR was found to be V3/T1/S3 (voltage of 170 V, pulse duration of 10 μs, and tool speed of 800 rpm). The calculated value of MRR (341,264.94 μm3/s) at the optimum level of input parameters was found to be close to the experimental MRR (340,727 μm3/s). The percentage error between the experimental and calculated value of MRR at the optimum level is very low as 0.15%. This indicates that the developed statistical model is quite significant in predicting MRR during μEDM of CFRP. POLYM. COMPOS., 40:4033–4041, 2019. © 2019 Society of Plastics Engineers

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Section: Introductionmentioning

confidence: 99%

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

2019

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“…It has also been observed that an increase in capacitance allows more energy to be stored during the process, improving the stabilization of the process. This generates a constant material removal improving the final surface quality [ 25 , 33 ].…”

Section: Resultsmentioning

confidence: 99%

“…Their study highlights the relationship between voltage and capacitance through a parameter called “discharge energy”. They establish that high values of discharge energy increase the rate of material removal as well as electrode wear [ 33 ]. Conversely, lower values of this parameter result in more controlled machining, improving the surface quality of the holes.…”

Section: Introductionmentioning

confidence: 99%

Design and Analysis of CFRP Drilling by Electrical Discharge Machining

et al. 2022

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The novelty of EDM machining as a drilling operation for composite materials means that there is no consensus on the influence of the parameters that optimise the final quality. For these reasons, a characterisation of the EDM drilling process of a unidirectional composite material has been developed. The influence of several cutting parameters has been related to the quality of the final hole obtained. Thus, macrogeometric aspects in terms of conicity and final diameter and microgeometric aspects in terms of surface quality have been evaluated. In addition, the final state of the material and the wear of the electrode have been evaluated by visual inspection, allowing the range of cutting parameters that offer the best performance to be established. Finally, a series of contour diagrams based on predictive models have been obtained to establish a direct relationship between input and output variables.

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“…In the Taguchi design [58], the decision parameter of the methodology is the signal-to-noise (S/N) ratio value. The optimal parameter combination is based on the maximum S/N ratio value [59][60][61]. The denominator of the S/N ratio value represents the disturbing effect of the uncontrollable noise factors of the process.…”

Section: Comparative Studymentioning

confidence: 99%

An experimental investigation for parametric appraisal of electrohydrodynamic-driven microfabrication approach using teaching and learning-based optimization

Das

Roy

Murmu

2020

J Braz. Soc. Mech. Sci. Eng.

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Electrohydrodynamic (EHD)-based microfabrication process is a novel high-resolution pattern generation technology for micro/nanoscale system fabrication. Achieving tiny droplets during deposition has been a critical issue for the further development of this new emerging technology. It is imperative to identify the proper fabrication parameters to get the desired resolution operation. In the current study, first, an experimental EHD microfabrication setup is developed, and then experiments are carried out to search for an operating condition, which can promote high-resolution droplet generation. The experiments are planned by design of experiment scheme. The influence of the operating control parameters such as nozzle to substrate gap, voltage and the supply rate of the material on deposited droplets diameter is investigated in the current work. Characterization study reveals that nozzle to substrate gap and supply rate have a positive effect on deposition behavior, whereas voltage has a negative association with the droplet resolution. For better control of the EHD process, a causal relationship is developed between process control and performance parameter. A metaheuristic search algorithm named teaching and learning-based optimization (TLBO) is employed to find out the optimal operating environment of the EHD process. The results are compared with the traditional robust parameter design approach, and the authors found that TLBO performs more effectively for resolution improvement in the EHD-driven microfabrication process. Moreover, the sequence in which the control parameters govern the fabrication process is identified and reported.

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Fabrication of micro holes in CFRP laminates using EDM

Cited by 49 publications

References 17 publications

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

A study of material removal and surface characteristics in micro‐electrical discharge machining of carbon fiber‐reinforced plastics

Design and Analysis of CFRP Drilling by Electrical Discharge Machining

An experimental investigation for parametric appraisal of electrohydrodynamic-driven microfabrication approach using teaching and learning-based optimization

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