Abstract
Metal hybrid fibre laminates (MHFLs) are gaining extensive attention due to their low weight-high strength and superior durability, which are used for primary constructions in a comprehensive application of aerospace and automobile industries. However, machining intricate shapes in MHFL is a challenge ahead of conventional machining processes. Hence, the present work aims at the machinability study of Titanium metal cored basalt/flax fibre laminate by using ultrasonic frequency vibration coupled wire electrical discharge machining (UFV-WEDM). The process- variables such as pulse on (Ton), pulse off (Toff), current (I), cutting angle (CA), and servo voltage (SV) coupled with ultrasonic frequency vibration (UFV) are varied at experimentation designed by using the Central Composite Design (CCD). The machined surface is characterized by the material removal rate (MRR) and surface roughness (SR). The empirical findings show that the servo voltage significantly influences MRR (73.93 %) and SR (70.02 %). The performance sequence order of significant influencing parameters is SV > Toff>CA > Ton>I. The Desirability analysis generated the optimum setting for minimizing the SR & maximizing MRR is Ton = 16 μs, Toff =14 μs, SV = 70 V, I = 3 A and CA = 30°. Scanning Electron Microscopic, 3D topography and atomic force microscopic (AFM) images were used to perform the micro-analysis on the machined surface of MHFL.
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