Exemplary approach using tool rotation-assisted µ-ECDM for CFRP composites machining

Abstract

Carbon fiber-reinforced polymer (CFRP) composites are an advanced composite material class due to their remarkable properties such as high load-carrying capacity and low density. CFRP composites have enormous applications in aerospace, biomedical, automobile, etc. Machining the CFRP composite is need of the day, but issues like delamination, fiber pullouts, workpiece damage, etc. have made it difficult. These limitations can be surpassed by the micro-electrochemical corona discharge machining (µ-ECDM) process. Although the process has showcased high process capability and great versatility in machining conducting and non-conducting materials, the process has limitations in machining holes deeper than 300 µm because of insufficient electrolyte supply at the machining zone. Aiding assistance to the process can overcome the limitation by enhancing electrolyte availability. Therefore, an experimental analysis is carried out by generating through holes on the CFRP composite using a tailor-made rotating tool-assisted micro-electrochemical corona discharge machining (RT-µ-ECDM) system. The process parameters, voltage, concentration, duty factor, and tool rotation rate are taken at three levels. The materials removal rate and overcut as machining characteristics were analyzed. The multi-response optimization using JAYA algorithm and R-method is used to obtain the optimal process parameters. The experimental investigation suggests RT-µ-ECDM system can machine through holes on CFRP composite. © 2022 Taylor & Francis.