Multi Response Optimization of ECDM Process for Generating Micro Holes in CFRP Composite Using TOPSIS Methodology

Area of Science:

• Materials Science
• Manufacturing Engineering
• Composite Materials Machining

Background:

• Carbon Fiber Reinforced Polymer Composites (CFRPCs) are crucial in aerospace, automotive, and electronics.
• Existing machining methods for CFRPCs face limitations, hindering widespread adoption.
• Precise micro-hole fabrication is essential for CFRPC applications.

Purpose of the Study:

• To investigate the Electrochemical Discharge Machining (ECDM) process for micro-hole drilling in CFRPCs.
• To optimize ECDM parameters for improved material removal rate (MRR) and reduced overcut.
• To evaluate the surface quality of micro-holes produced by ECDM.

Main Methods:

• Experimental design using an L9 orthogonal array.
• Input parameters: applied voltage, electrolyte concentration, and inter-electrode gap.
• Output parameters: Material Removal Rate (MRR) and overcut.
• Multi-response optimization using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS).

Main Results:

• Optimized ECDM parameters using TOPSIS significantly improved MRR and reduced overcut.
• Overcut reduced from 150 µm to 48 µm.
• MRR improved from 2.232 mg/min to 2.1267 mg/min.
• Machined micro-holes exhibited superior surface quality with fewer micro-cracks and uniform diameter.

Conclusions:

• ECDM is a viable and effective method for precise micro-hole machining of CFRPCs.
• TOPSIS methodology successfully optimized ECDM parameters for enhanced performance.
• The optimized ECDM process yields high-quality micro-holes suitable for demanding applications.