The Machinability Characteristics of Multidirectional CFRP Composites Using High-Performance Wire EDM Electrodes

Due to the abrasive nature of material, conventional machining CFRP composites is typically characterised by high mechanical forces and poor tool life, which can have a detrimental effect on workpiece surface quality, properties, dimensional accuracy, and, ultimately, functional performance. The present paper details an experimental investigation assess feasibility wire electrical discharge (WEDM) as alternative for cutting multidirectional composite laminates using high-performance electrodes. A full factorial array comprising total 8 tests was employed evaluate varying ignition current (3 5 A), pulse-off time (8 10 µs), type (Topas Plus D Compeed) material removal rate (MRR), kerf width, roughness, damage. Compeed achieved lower MRR up ~40% compared with Topas when operating at comparable parameters, despite having higher conductivity. Statistical involving analysis variance (ANOVA) showed that only significant factor impacting rate, percentage contribution ratio 67.76%. In terms cut accuracy resulted in marginally wider kerfs (~8%) roughness (~11%) wire, maximum recorded values 374.38 µm 27.53 Sa, respectively. Micrographs from scanning electron microscopy revealed presence considerable fibre fragments, voids, adhered re-solidified matrix machined surfaces, likely due thermal WEDM process. research demonstrated viability relatively thick (9 mm) without need employing conductive assistive advanced coated electrodes used combination levels increased ~15 mm3/min.