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Multi-objective optimization of hole dilation at inlet and outlet during machining of CFRP by μEDM using assisting-electrode and rotating tool
The International Journal of Advanced Manufacturing Technology ( IF 3.4 ) Pub Date : 2020-08-30 , DOI: 10.1007/s00170-020-05987-3
Hrishikesh Dutta , Kishore Debnath , Deba Kumar Sarma

Machining of carbon fiber-reinforced polymers (CFRP) by traditional processes is quite challenging as damages namely breakage of fibers, delamination, and fiber pull-out occur during machining. Therefore, non-traditional machining process namely micro-electrical discharge machining (μEDM) is emerging to produce precise and high-quality features in CFRP. In this work, for machining CFRP, μEDM method coupled with rotary tool and assisting-electrode was used for efficient spark generation. Grey relational analysis (GRA) was performed to optimize the machining parameters viz. voltage (100, 130, 160, and 190 V), pulse duration (10, 20, 30, and 40 μs), and tool speed (200, 300, 400, and 500 RPM) that affect the output responses namely hole dilation at inlet (HDin) and outlet (HDout). The optimal condition of input parameters was found to be V1/T1/S1 (100 V/10 μs/200 RPM). The voltage was observed to be the most affecting factor with a contribution of 90.95% while tool speed and pulse duration had a contribution of 5.91% and 1.48%, respectively. It was also found that the material removal mechanism was a complex phenomenon where sparking occurred both at end face and side surface of the tool. The deposition of pyrolytic carbon particles that helps in continuing the sparking was observed in the micrographic images obtained through field emission scanning electron microscope (FESEM). The burning of the matrix due to thermal effect and spalling was also evident which led to the removal of the material from the composite.



中文翻译:

使用辅助电极和旋转工具通过μEDM在CFRP加工CFRP时在入口和出口处的孔扩张的多目标优化

通过传统工艺加工碳纤维增强聚合物(CFRP)极具挑战性,因为在加工过程中会发生损坏,即纤维断裂,分层和纤维拔出。因此,非传统加工工艺,即微电火花加工(μEDM)不断涌现,以在CFRP中产生精确和高质量的特征。在这项工作中,为了加工CFRP,将μEDM方法与旋转工具和辅助电极结合使用以有效地产生火花。进行了灰色关联分析(GRA)以优化加工参数。电压(100、130、160和190 V),脉冲持续时间(10、20、30和40μs)和工具速度(200、300、400和500 RPM)会影响输出响应,即孔扩张入口(HD输入)和出口(HD输出))。发现输入参数的最佳条件是V1 / T1 / S1(100 V / 10μs/ 200 RPM)。观察到电压是影响最大的因素,占90.95%,而工具速度和脉冲持续时间分别占5.91%和1.48%。还发现材料去除机理是一种复杂的现象,其中在工具的端面和侧面都产生火花。在通过场发射扫描电子显微镜(FESEM)获得的显微图像中观察到有助于继续火花的热解碳颗粒的沉积。由于热效应和剥落而引起的基质燃烧也是明显的,这导致从复合物中除去材料。

更新日期:2020-09-22
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