Dubey, Ankit Dhar;
Aryan, Omkar Raj;
Chaurasia, Satish;
Debnath, Kishore;
Siddiqui, Md Irfanul;
Ashraf, Intesaaf;
(2025)
Optimizing Electric-Discharge Milling for Microchannel Fabrication in 3D-Printed Composites Using Harris Hawk Optimization and Wire Electric-Discharge Ground Tools.
Journal of Materials Engineering and Performance
10.1007/s11665-025-12211-4.
(In press).
![[thumbnail of Ashraf_Revised Manuscript.pdf]](https://discovery.ucl.ac.uk/style/images/fileicons/text.png) |
Text
Ashraf_Revised Manuscript.pdf Access restricted to UCL open access staff until 30 September 2026. Download (1MB) |
Abstract
This study focuses on optimizing the microelectric-discharge milling (µEDM) process for fabricating microchannels in 3D-printed composites of onyx and carbon fiber, using gray relational analysis (GRA) and Harris hawk optimization (HHO). The composite specimens were micromachined via µEDM with tool electrodes of varying geometries—circular, triangular, and rectangular—crafted using wire electrical discharge grinding (WEDG). Key input parameters, including tool rotation (200, 600, and 100 RPM), tool geometry (circular, rectangular, and triangular), voltage (100, 150, and 200 V), and capacitance (33, 100, and 1000 pF), were selected to minimize machining time and dimensional deviation. A hybrid GRA-HHO technique determined the optimal configuration, revealing the triangular tool as superior due to its enhanced erosion rate and effective debris removal. Optimal input conditions of 1000 RPM, 200 V, and 1000 pF capacitance resulted in the lowest machining time (89.3 min) and dimensional deviation (20.5 μm). Compared to Taguchi, the hybrid GRA-HHO optimization approach yielded an 18.81% reduction in machining time and a 6.39% improvement in dimensional accuracy. Morphological analyses of the machined surfaces validated that the triangular tool minimized overcutting and produced uniform microchannels. This approach offers valuable insights into the micromachining of 3D-printed composites, especially for applications in the automotive and aerospace sectors where precision and efficiency are critical.
| Type: | Article |
|---|---|
| Title: | Optimizing Electric-Discharge Milling for Microchannel Fabrication in 3D-Printed Composites Using Harris Hawk Optimization and Wire Electric-Discharge Ground Tools |
| DOI: | 10.1007/s11665-025-12211-4 |
| Publisher version: | https://doi.org/10.1007/s11665-025-12211-4 |
| Language: | English |
| Additional information: | This version is the author accepted manuscript. For information on re-use, please refer to the publisher’s terms and conditions. |
| Keywords: | 3D printing; µEDM; composites; EDG; GRA-HHO; microchannel; morphology |
| UCL classification: | UCL UCL > Provost and Vice Provost Offices > UCL BEAMS UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Mechanical Engineering |
| URI: | https://discovery.ucl.ac.uk/id/eprint/10218806 |
Archive Staff Only
 |
View Item |
