Abstract
This study presents the analysis of wire-cut electro-discharge machining (WIRE-EDM) of polymer composite material (PCM). The conductivity of the workpiece is improved by using 1 mm thick titanium plates (layers) sandwiched on the PCM. Input process parameters selected are variable voltage (50–100 V), pulse duration (5–15 μs), and pause time (10–50 μs), while the cut-width (kerf) is recognized as an output parameter. Experimentation was carried out by following the central composition design (CCD) design matrix. Analysis of variance was applied to investigate the effect of process parameters on the cut-width of the PCM parts and develop the theoretical model. The results demonstrated that voltage and pulse duration significantly affect the cut-width accuracy of PCM. Furthermore, the theoretical model of machining is developed and illustrates the efficacy within the acceptable range. Finally, it is concluded that the model is an excellent way to successfully estimate the correction factors to machine complex-shaped PCM parts.
Highlights
Francesco ModicaRecently, replacing metallic machine parts with composite material has been seen as a potential alternative to various issues, including high metal costs, rusting, and the weight of the components
The experimental work reveals the dependence between the WIRE-EDM cut width and processing parameters such as voltage, pulse-on time, pulse-off time
These results can be expedited to adjust the size of the electrode tool (ET) and ensure precision in the WIRE-EDM of polymer composite material (PCM) (VKU-39) workpieces
Summary
Francesco ModicaRecently, replacing metallic machine parts with composite material has been seen as a potential alternative to various issues, including high metal costs, rusting, and the weight of the components. In the modern machining industry, composite materials that possess similar or even enhanced physical and mechanical properties compared to metals are highly encouraged [1,2,3]. The development of light-weight PCMs plays a significant role in aviation and many critical industrial applications. These materials are economically efficient and reduce the CO2 emission load [1]. The filler/reinforcement used in a PCM determines its mechanical properties, such as strength, stiffness, and deformability. The filler used may be carbon/ceramic fibers These fibers have good physical and mechanical properties. These fibers are converted into fabrics by weaving [5,6,7]. A typical PCM is shown in Figure 1a, and the weaving pattern of the fibers forms the reinforcement phase and the possible defects in conventional machining
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