Role of ceramics in machining of composite materials: A comprehensive review

Abstract

The current review article explores advancements in machining of metal matrix composites (MMCs), polymer-matrix composites (PMCs), and ceramic matrix composites (CMCs), with a focus on the critical role of ceramic abrasives. Processes, such as slotted electrical discharge abrasive grinding (SEDAG) and electrochemical discharge grinding machining, utilize both thermal (spark erosion) and mechanical (abrasive) actions, effectively balancing material removal and minimizing damage during machining of MMCs. For PMCs, rotary ultrasonic face grinding combines grinding with ultrasonic vibrations, reducing friction and cutting forces. In CMCs, advanced methods, such as laser-assisted grinding (LAG) and laser-ablating-assisted grinding (LAAG), are particularly effective. LAG preheats the material, softening it for easier removal, whereas LAAG ablates the material directly, reducing cutting forces and subsurface damage. These methods are tailored to the material properties of each composite, optimizing removal rates and surface quality. The research emphasizes that ceramic abrasives significantly improve machining efficiency and surface integrity when optimized with the right combination of parameters. By discussing the interaction of abrasives with composite materials, this review article provides key insights into improving machining processes, making it a valuable reference for researchers seeking to enhance machinability of composite materials across various applications.