Fabrication of Micro-Hole in 3D Printed CFRP Composite by Electrical Discharge Machining Process

Abstract

Carbon fiber-reinforced polymer (CFRP) composite has extensive application in several industries, including the automotive and aerospace industries. Fabrication of micro-features in CFRP composite is an important process that is frequently performed for various applications including for micro-products and micro-components. The fabrication of precise micro-features in CFRP composite is difficult to achieve by conventional means, even by additive manufacturing (AM). Thus, in this study, the machinability characteristics of the CFRP composite were experimentally investigated. CFRP composite was fabricated by using the AM technique. The different process parameters of 3D printing (infill density and layer sequence) and micro-EDM (voltage, capacitance, and tool rotation) were considered to investigate their effect on the hole quality and productivity. The optimization of the different parameters chosen for the purpose of the investigation was also carried out. The important process parameters that have an impact on the process were identified and analyzed. The better machining performance of CFRP composite was noticed at higher infill density and alternative fiber arrangement. The capacitance was the most significant parameter among all the EDM parameters to produce good quality micro-holes in CFRP composite.