Analysis of Mass Concentration and Morphology of Fume Particles during ECDM of CFRP Composites

Abstract

Electrochemical discharge machining (ECDM) is a hybrid method used to generate micro-features in hard and brittle materials (glass, ceramics, and composites) in aerospace, microelectromechanical systems (MEMS), and microfluidic applications. A significant improvement was observed in ECDM process but the effect of the process on the health of working operator are rarely investigated. Sustainability in manufacturing is a major concern for a better environment and safety of human operators. In this paper, analysis of fumes mass concentration (FMC), size and morphology of fume particles, and composition of fume particles along with their biological effects are studied during ECDM of CFRP composites. FMC was calculated by varying the concentration of electrolyte from 20 to 50% and duty cycle from 60 to 90% for a fixed sampling duration of 30 minutes. SEM images indicated the presence of spherical, irregular, and loosely packed fumes particles in the fumes generated during machining. EDS was also performed to study the chemical composition of fumes particles.