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A Study of Added SiC Powder in Kerosene for the Blind Square Hole Machining of CFRP Using Electrical Discharge Machining

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Abstract

Carbon Fiber Reinforced Polymers (CFRPs) have been applied potentially for various application components owing to their lightweight and better mechanical properties. However, the machining of CFRP has been observed to be poor machinability due to the properties of the CFRP composites. Micro-feature fabricating on CFRP macro-component is a challenging task due to the selection of inadequate process parameters and machines. However, micron-level blind square holes are required in CFRPs for proposing the applications of micro-robotics, micro-vibration measurements, and micro-detection of cracking. These square holes produced on CFRP have the difficult task of being machined using the Electrical Discharge Machining (EDM) process. In this research, the effects of concentration of silicon carbide, pulse duration, duty cycle, and current on squareness, hole depth, and surface roughness of CFRPs are analyzed using Electrical Discharge Machining (EDM) with the square copper electrode. The input parameters, the various percentage of concentration of silicon carbide, pulse duration, duty cycle, and current for EDM are selected. The responses, squareness, hole depth, and surface roughness are considered. Also, an electrode wear length and surface defects have been analyzed. The modeling has been performed for selected responses. Additive Ratio Assessment (ARAS) is used for obtaining optimum parameters. The overall analysis found that the silicon carbide concentration and pulse duration are greatly affected all the responses. Also, the square electrodes produced unstable spark phenomena in the EDM process.

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Acknowledgments

The authors thank the COVAI EDM at Coimbatore for providing a machining facility. The authors are also thankful to Periyar Maniammai Institute of Science & Technology at Vallam for providing a scanning electron microscopy facility.

Contributions

PV Arul Kumar: Conceptualization, Methodology, Writing Reviewing discussion and Editing. J. Vivek: computation, Methodology, Software, Writing discussion and N. Senniangiri: Conceptualization and analysis, Writing-review, writing the manuscript, Methodology, Software, and writing – discussion, S. Nagarajan: review manuscript language, B. Alshahrani: review manuscript language, K. Chandrasekaran: review manuscript language.

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The authors did not receive support from any organization for the submitted work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Bharath Niketan Engineering College, Aundipatty, Tamil Nadu, 625536, India

    PV Arul Kumar

  2. Department of Mechanical Engineering, Solamalai College of Engineering, Madurai, Tamil Nadu, 625020, India

    J. Vivek

  3. Department of Mechanical Engineering, Nandha Engineering College, Erode, Tamil Nadu, 628052, India

    N. Senniangiri

  4. Department of Mechanical Engineering, College of Engineering and Technology, Mettu University, Post Box. No 318, Mettu, Ethiopia

    S. Nagarajan

  5. Department of Mechanical Engineering, MAM School of Engineering, Trichy, Tamil Nadu, 621105, India

    K. Chandrasekaran

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Kumar, P.A., Vivek, J., Senniangiri, N. et al. A Study of Added SiC Powder in Kerosene for the Blind Square Hole Machining of CFRP Using Electrical Discharge Machining. Silicon 14, 1831–1849 (2022). https://doi.org/10.1007/s12633-021-01243-9

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