Micromachining of Carbon Fiber Reinforced Plastics (CFRPs) is essential for numerous applications in several industries such as aerospace, automotive, defense, shipping, sporting goods, and biomedical industries. The major challenge in machining CFRP by electrical discharge machining (EDM) is due to the non-conductivity of epoxy material which is used as a binder for manufacturing these CRFPs. This study attempts a novel, yet simple approach to ensure the conductivity of the work piece through the entire machining process. Experiments were carried out in this work to assess the feasibility of machining high aspect ratio micro-holes in CFRP by micro EDM. The effect of process parameters such as voltage and feed-rate on the hole quality was studied. Using optimal process conditions, micro hole of 2500 µm deep with an aspect ratio of over 11 was achieved.

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