Silicon carbide particulates-reinforced polymer matrix composites have gained a reputation among composite materials due to their excellent mechanical properties. But these materials are categorized as hard to machine materials due to hardness and the abrasive nature of reinforcing particulates. For that purpose, it becomes necessary to develop a machining method which can be extensively used for machining of these types of materials. In this paper, an attempt has been made to optimize machining parameters of electrochemical discharge drilling process through response surface methodology. The experimentation was planned as per Box–Behnken design. Three process parameters, i.e. electrolytic concentration, voltage and inter-electrode gap were analyzed to explore their influence on output quality characteristics. The parameters voltage and inter-electrode gap are identified as most significant parameters for material removal rate and over cut, respectively. The surface plots were generated to study the effect of machining parameters as well as their interaction on output quality characteristics. The morphology of drilled hole was analyzed by scanning electron microscopy. A novel technique of measuring adjusted delamination factor ( F da ) was adopted to analyze surface quality of machined zone. The analyzed results indicate that irregular damage pattern induced during drilling of composites can be effectively measured using adjusted delamination factor.

中文翻译：

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杂化聚合物基复合材料电化学放电加工 (ECDM) 过程中的实验研究

碳化硅颗粒增强聚合物基复合材料因其优异的机械性能而在复合材料中享有盛誉。但由于增强颗粒的硬度和磨蚀性，这些材料被归类为难加工材料。为此，有必要开发一种可广泛用于加工这些类型材料的加工方法。本文尝试通过响应面法优化电化学放电钻孔工艺的加工参数。实验是按照 Box-Behnken 设计计划的。分析了电解液浓度、电压和极间间隙三个工艺参数，探讨了它们对输出质量特性的影响。参数电压和电极间间隙分别被确定为材料去除率和过切的最重要参数。生成表面图是为了研究加工参数的影响以及它们对输出质量特性的相互作用。通过扫描电子显微镜分析钻孔的形貌。采用测量调整分层因子（F da ）的新技术来分析加工区的表面质量。分析结果表明，使用调整后的分层因子可以有效地测量在复合材料钻孔过程中引起的不规则损伤模式。生成表面图是为了研究加工参数的影响以及它们对输出质量特性的相互作用。通过扫描电子显微镜分析钻孔的形貌。采用测量调整分层因子（F da ）的新技术来分析加工区的表面质量。分析结果表明，使用调整后的分层因子可以有效地测量在复合材料钻孔过程中引起的不规则损伤模式。生成表面图是为了研究加工参数的影响以及它们对输出质量特性的相互作用。通过扫描电子显微镜分析钻孔的形貌。采用测量调整分层因子（F da ）的新技术来分析加工区的表面质量。分析结果表明，使用调整后的分层因子可以有效地测量在复合材料钻孔过程中引起的不规则损伤模式。