INVESTIGATION ON HYBRID FIBER METAL LAMINATE USING ULTRASONIC VIBRATION-COUPLED MICROWIRE ELECTRICAL DISCHARGE MACHINING

M. Karthikeyan (), S. Muthu Vijaya Pandian and R. Vijayakumar
Additional contact information
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

Surface Review and Letters (SRL), 2025, vol. 32, issue 02, 1-19

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.

Keywords: IN-625; aramid; carbon; ultrasonic; electrical; desirability (search for similar items in EconPapers)
Date: 2025
References: Add references at CitEc
Citations:

Downloads: (external link)
http://www.worldscientific.com/doi/abs/10.1142/S0218625X24501142
Access to full text is restricted to subscribers

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:wsi:srlxxx:v:32:y:2025:i:02:n:s0218625x24501142

Ordering information: This journal article can be ordered from

DOI: 10.1142/S0218625X24501142

Access Statistics for this article

Surface Review and Letters (SRL) is currently edited by S Y Tong

More articles in Surface Review and Letters (SRL) from World Scientific Publishing Co. Pte. Ltd.
Bibliographic data for series maintained by Tai Tone Lim ().