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

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- μ WEDM). Since UV- μ WEDM parameters significantly impact the erosion rate ( E R ) and surface undulation ( S U ), the main objective was to identify the optimal machining parameters. The input variables include the pulse on ( P on ), pulse off ( P off ), current ( I C ), cutting inclination ( C I ), and servo voltage ( S V ) coupled with ultrasonic vibration (UV). The empirical findings show that the servo voltage ( S V ) significantly impacts E R (73.93%) and S U (70.02%). The performance categorization order of significant influencing variable is S V > P off > C I > P on > I C . The desirability interpretation generated the optimum setting for minimizing S U and maximizing E R is P on = 8 μ s, P off = 1 4 μ s, S V = 5 0 V, I C = 3 A, and C I = 3 0 ∘ . 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- μ WEDM is crucial to minimize damage and improve the quality of HFMLs. [ABSTRACT FROM AUTHOR]