Optimizing processing parameters in electrical discharge milling of CFRP using metaheuristics

The micro-channel fabrication in carbon fiber-reinforced polymer (CFRP) composite through electrical discharge machining (EDM) process followed by the comprehensive study of dimensional deviation in the conceived micro-channels are presented in this work. The factors namely, voltage (V), tool rotational speed (TRS), and feed rate (FR) were considered for assessing their impact on channel width deviation (CWD). In addition to the variance analysis, two potential metaheuristic optimizers, the Butterfly optimization algorithm (BOA) and the Spotted Hyena optimization algorithm (SHO) were used to identify the optimal operating parameters of the aforementioned process. The BOA revealed that the optimal process variables were FR = 5.99 µm/s, V = 150 volt, and TRS = 577.08 rpm for a CWD = 74.96 µm. In contrary, SHO revealed that FR = 5.99 µm/s, V = 150 volt, TRS = 542.96 rpm, and CWD = 74.53 µm were the corresponding optimal values. Overcuts were observed in the fabricated micro-channels and a detailed illustration of the mechanism of overcut formation was provided.