MACHINING OF

COMPOSITES
 INTRODUCTION

• Composites are combinations of two or more

materials. This is done to gain benefit from
both material properties.
• Composite material attaining worldwide
popularity for manufacturing, aerospace and
automobile industries .
• In machining of composite materials, reducing
damage and reliable surface roughness
characterization is necessary
• Composite materials are very hard to machine
due to their structural non homogeneity and
anisotropic nature.
 MACHINING OF COMPOSITES

Machining
Composites

Non-
Conventiona
Conventiona
l
l

Orthogonal Milling
Drilling Turning
Cutting

EDM WJM AJM LBM PAC USM

 CONVENTIONAL MACHINING
• Composites can be machined by many conventional machining processes such as turning,
milling, drilling, tapping, grinding, honing, sawing.
• Results shows:
Huge amount of tool wear
Poor machineability
Poor surface quality
Low accuracy
 POLYCRYSTALLINE DIAMOND TOOLS
• Accelerated wear occurs on cutting
tools.
• Polycrystalline diamond tools gives
better results.
• Quality of chip formation depends on
fibre orientation and cutting speed.
• Surface finish is also affected.
NON CONVENTIONAL MACHINING

ELECTRIC DISCHARGE MACHINE

 ELECTRIC DISCHARGE MACHINE

• The selection of proper machining

parameters is an important criterion while
machining in EDM and also the expertise
of the operator.
• The pulse duration had significant effect
on material removal rate and peak current
was the most effective parameter for
surface roughness.
• It was found out that material removal
rate (MRR) and tool wear rate increased
with increase in current.
WIRE ELECTRIC DISCHARGE MACHINE
 WIRE ELECTRIC DISCHARGE MACHINE

• Wire electrical discharge

machining (WEDM) is a
thermal non-contact technique
of machining.
• Within the past decade, the
WEDM process is a competitive
and economical machining
• Used for Metal Matrix
Composites and ceramic
composites.
 APPLICATIONS
• Composite materials are widely used in the
aircraft manufacturing industries
• Railway sectors
• Defense
• Micro systems industries,
• Agriculture farm machinery
• Fiber-reinforced polymer composite pipes are
used for sewer upgrades and wastewater projects
• Composites help enable the use of wind and
solar power and improve the efficiency