Investigation on cutting of thin carbon fiber-reinforced polymer composite plate using sandwich electrode-assisted wire electrical-discharge machining

This paper presents the experimental investigation on cutting of thin carbon fiber-reinforced polymer (CFRP) composite plate by wire electrical-discharge machining (WEDM) with the aid of sandwich assisting-electrodes. The difficulties such as incomplete cut and deviation in machining path during WEDM of CFRP were avoided by using metal plates (H13 steel) as assisting-electrodes. The spark initiation during WEDM of CFRP is difficult without exposing the carbon fiber as fibers are embedded into nonconductive polymer in CFRP. Thus, in this work, assisting-electrode was used to initiate the sparking without changing the surface integrity of the CFRP. The one-factor-at-a-time analysis was applied to study the effect of input parameters namely input current (2, 4, 6, 8, 10, and 12 A), pulse on time (10, 20, 30, 40, 50, and 60 µs), pulse off time (10, 20, 30, 40, 50, and 60 µs), and voltage (70 and 90 V) on the cutting time and the machined surface morphology. A decreasing trend was observed for cutting time with an increase in the current. Whereas, the cutting time was increased with an increase in the pulse off time. It was also observed that the cutting time initially increased with the pulse on time (10 to 30 µs) and then started decreasing with a further increase in the pulse on time (40 to 60 µs). The cutting time was significantly reduced at a higher level of voltage (90 V) when compared one-on-one with lower voltage level (70 V). In this study, microscopic analysis of the surface morphology was also extensively investigated which was not investigated earlier. The investigation showed damages such as breakage of carbon fibers, fiber-matrix debonding, and matrix cracking during WEDM of CFRP using sandwich assisting-electrode.

Investigation an assisting electrode powder mixed electrical discharge machining of nonconductive ceramic

It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

Electric Discharge Machining of Conducting Ceramics - A Review

Electrical Discharge machining (EDM) is a nonconventional machining technique, which has been widely used to produce dies and mold. Harder Materials can be machined into complex shapes as long as they conduct electricity. Recent advances in the technologies brought the development of new engineering materials, which are hard to machine with traditional machining processes. Being one of these materials, ceramics possess some unique properties like piezoelectricity and tribological properties which are not found in metal and polymers. EDM is capable of machining these ceramics, given these materials have an adequately high electrical conductivity. Preparing conducting ceramics is pre-requisite for incorporating ceramics in EDM. Different techniques such as compaction, tape casting, extrusion, injection molding and slip casting are used form green ceramic body. These green bodies are subsequently sintered to obtain ceramic parts. Adding conducting elements in the ceramics while processing results in conducting ceramics. These additions increase hardness but fracture toughness of body is compromised. Ceramic parts can also be machined by using assisting electrode and pyrolytic carbon technique. This paper discusses the various methods of shaping conducting ceramics and its machining characteristics for EDM application

Powder Mixed Micro Electro Discharge Machining of Aluminium Nitride Ceramic

Advanced ceramic materials possess superior mechanical characteristics in terms of hardness, wear resistance, fracture toughness and flexural strength. However, these materials experience machining limitations due to their hardness. Machining process of such materials requires high cutting forces and results in high tool wear. Electro- discharge machining (EDM) can be considered as an alternative machining process for advanced ceramics, since this technique is a non-contact machining process, it does not involve high cutting forces but experiences moderate tool wear. However, EDM requires materials to have certain level of electrical conductivity, therefore, non-conductive and semi-conductive ceramic materials experience challenges during machining process. Assisting Electrode Method was suggested as a solution for machining of non-conductive ceramics by EDM. In this method, conductive layer is applied on top of non-conductive ceramics and thus workpiece can be machined by EDM process using residual conductive layer. In this study, coating consisting of three layers, where silver nanoparticles were sandwiched between two layers of silver and copper on top, was used as assisting electrode to machine Aluminium Nitride (AlN) ceramics by silver nanoparticles mixed micro-EDM. Successful machining of AlN was demonstrated and blind micro hole with higher than three aspect ratio was achieved.

Micro Electro Discharge Machining of Nonconductive Ceramic: The Issue of Spalling

Nonconductive ceramic materials are used in many engineering applications such as car brake, turbine blade, and hip-bone replacement because of its high dimensional accuracy, corrosion and wear resistant, and biocompatibility. These materials are usually processed with diamond grinding and limited laser applications such as cutting, drilling and scribing. Specific shapes and profiles are still difficult and costly to machine using these processes. Electrical discharge machining (EDM), extensively used for various shapes and profiles on conductive materials having minimum electrical conductivity of 0.10 S.cm-1. It is not directly applicable on nonconductive ceramic materials due to its very low electrical conductivity (<10-10 S.cm-1). However, recently EDM is used on nonconductive materials with the aid of assisting electrode to initiate the spark between conductive tool electrode and nonconductive workpiece. The available material removal models of EDM are based on single spark erosion with uniform melting and vaporization of workpiece materials. However, in EDM of nonconductive ceramics, material removal is not uniform because of random spalling due to alternating thermal stress. In addition, it is difficult to create single spark erosion on a nonconductive ceramic workpiece as initial sparks are occurred between tool electrode and assisting electrode attached to workpiece. This paper presents the empirical factor for the estimation of spalling along with melting and vaporization through experimental study. Model of material removal rate as a function of capacitance and voltage are developed in micromachining of nonconductive zirconium oxide (ZrO2) using (R-C) pulse type micro-EDM. The single spark erosion volume is derived from the fundamental principle of melting and vaporization. An empirical correction factor is introduced to compensate random spalling and multi-spark erosion effect.