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Investigation On Hybrid Fiber Metal Laminate Using Ultrasonic Vibration-Coupled Microwire Electrical Discharge Machining

Author

Listed:
  • M. KARTHIKEYAN

    (Anna University, Chennai 600025, Tamil Nadu, India)

  • S. MUTHU VIJAYA PANDIAN

    (��Department of Electrical and Electronics Engineering, SNS College of Technology, Coimbatore 641035, Tamil Nadu, India)

  • R. VIJAYAKUMAR

    (��Department of Mechanical Engineering, GRT Institute of Engineering and Technology, Tiruttani 631209, Tamil Nadu, India)

Abstract

This study examines the machinability of hybrid fiber metal laminates (HFML), which are made by nickel–chromium alloy (IN-625) metal-cored carbon (Ca)/aramid (Ar) fiber laminate using ultrasonic vibration-coupled microwire electrical discharge machining (UV-μWEDM). Since UV-μWEDM parameters significantly impact the erosion rate (ER) and surface undulation (SU), the main objective was to identify the optimal machining parameters. The input variables include the pulse on (Pon), pulse off (Poff), current (IC), cutting inclination (CI), and servo voltage (SV) coupled with ultrasonic vibration (UV). The empirical findings show that the servo voltage (SV) significantly impacts ER (73.93%) and SU (70.02%). The performance categorization order of significant influencing variable is SV>Poff>CI>Pon>IC. The desirability interpretation generated the optimum setting for minimizing SU and maximizing ER is Pon=8μs, Poff=14μs, SV=50V, IC=3A, and CI=30∘. Scanning electron microscopic (SEM) images were used to perform the micro-interlayer analysis on the machined surface. Moreover, creating an appropriate HFML is necessary to cut various shapes and sizes to satisfy the demands of diverse applications. 60% of components in the aerospace sector are reportedly rejected in real time due to dimension departure, poor surface finish, and damage found in the final assembly. Investigating the viability of cutting-edge machining techniques like UV-μWEDM is crucial to minimize damage and improve the quality of HFMLs.

Suggested Citation

  • M. Karthikeyan & S. Muthu Vijaya Pandian & R. Vijayakumar, 2025. "Investigation On Hybrid Fiber Metal Laminate Using Ultrasonic Vibration-Coupled Microwire Electrical Discharge Machining," Surface Review and Letters (SRL), World Scientific Publishing Co. Pte. Ltd., vol. 32(02), pages 1-19, February.
    • Handle: RePEc:wsi:srlxxx:v:32:y:2025:i:02:n:s0218625x24501142
    DOI: 10.1142/S0218625X24501142
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