Experimental study demonstrates improved drilling performance in thick sisal fiber composites via magnetic electrochemical discharge machining, indicating higher precision and speed.
This study investigates magnetic-field-assisted electrochemical discharge machining (MA-ECDM) for drilling thick sisal fiber-reinforced polymer composites using a carbon nanotube (CNT)-enhanced NaOH electrolyte. The combined effects of tool rotation, magnetohydrodynamic stirring, and CNT-assisted electric-field intensification improved gas-film stability and localized spark discharges. Compared with conventional ECDM and MA-ECDM, CNT-assisted MA-ECDM increased the material removal rate by 22% and 14%, while reducing hole overcut by 40% and 26% and taper angle by 63% and 55%, respectively. CNT addition also reduced the peak electrolyte temperature from 58°C to 50°C and cooling time from 11 to 7 min. Particle swarm optimization identified optimal conditions of 60.5 V, 1050 mg/L CNT, and 750 rpm, producing 0.392 mg/s MRR, 86.21 µm overcut, and 0.18° taper angle, with minimal errors during experimental validation trials overall.
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Singh et al. (2026) studied this question.
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