Sameh Habib

Effect of cutting direction on machining of carbon fibre reinforced plastic by electrical discharge machining process

In this study, the electrical discharge machining (EDM) characteristics and its removal mechanism for one and two directional carbon fibre reinforced plastic (CFRP) composite was evaluated. Also, an investigation about the influence of carbon fibre direction to machining direction was discussed to attain high performance of EDM process. Then EDM characteristics with two different combinations of machining direction and carbon fibre direction were compared. EDM machining characteristics such as material removal rate, electrode wear rate, surface roughness and SEM images were determined. Experimental results clarified that the material removal mechanism in the EDM for one directional CFRP when the machining direction is perpendicular to the fibre direction is different from that in parallel machining. Also, the EDM machining for two directional CFRP is different from that for one direction. Therefore, efficient EDM for CFRP is possible by selecting appropriate machining direction to fibre direction and the type of CFRP according to its fibre direction.

Influence of electrical discharge machining parameters on cutting parameters of carbon fiber-reinforced plastic

ABSTRACT Today the use of high-strength carbon fiber-reinforced plastics (CFRP) composite as a material for many engineering applications is showing an increasing demand in the industry. These composites are replacing the traditional use of steel because they offer many advantages such as very light weight, high strength, and high stiffness associated with good corrosion-resistant properties. Unfortunately, there is little technological knowledge on the electrical discharge machining (EDM) process of high-strength composite materials, especially about the CFRP. In this work, a study has made into the possibility of using EDM process as a means of machining CFRP composite. Various cutting conditions such as peak current, pulse-on time, pulse-off time and open-circuit voltage were selected to perform electrical discharge machining. The effect of electrode rotation was also studied. Optimum cutting conditions and machine settings for EDM were chosen for machining CFRP composites.

Mathematical Modelling for Wire Electrical Discharge Machining of Aluminum-Silicon Carbide Composites

The increased role of advanced materials in engineering design optimization has enhanced the development of new material types. Metal matrix composites now allow the designer to select needed material properties. A key in the use of these materials is the cost effective manufacturing and dimensional control of the designed parts. Composites are a new class of engineering materials which have a high potential for many industrial applications. The traditional methods of machining these materials are very slow and expensive, and can also cause strength degradation due to the formation of subsurface cracks or other defects. The WEDM process is one of the best alternatives, for machining an ever-increasing number of high-strength, non-corrosive and wear resistant materials such as Aluminum Silicon Carbide (AlSiC).

An Operating and Diagnostic Knowledge-Based System for Wire EDM

The selection of machining parameters and machine settings for wire electrical discharge machining (WEDM) depends mainly on both technologies and experience provided by machine tool manufacturers. The present work designs a knowledge-based system (KBS) to select the optimal process parameters settings and diagnose the machining conditions for WEDM. Moreover, the present results supply users of WEDM with beneficial data avoiding further experimentation. Various materials are tested and sample results are presented for improving the WEDM performance.