Effect of Cutting Environments on Drilling Induced Damage in GFRP Nanocomposites

2020 ◽  
Author(s):  
Panchagnula Kishore Kumar ◽  
Panchagnula Jayaprakash Sharma
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Glass Fiber Reinforced Plastic ◽  
Delamination Factor ◽  
Glass Fiber Reinforced ◽  
Solid Carbide ◽  
Torque Values

Abstract Drilling is most commonly used secondary machining process for structural joining of Glass Fiber Reinforced Plastic (GFRP) composites. Performing drilling operations on GFRPs/Multi-Walled CarbonNanoTubes (MWCNTs) reinforced GFRPs is really a challenging task due to their non-homogeneity and anisotropic behavior, which directs to generation of material damages. The prime focus of current work is to identify the suitable process parameters for enhancing the performance of drilling of GFRP nanocomposites. In this study, the drilling experiments are conducted on 0.3wt.% MWCNT-GFRP nanocomposites with solid carbide, TiCN and TiAlN coated drills (6mm diameter) under dry and chilled air cutting environments. The dry drilling experiments are conducted without any assistance of cooling fluid in ambient condition. The chilled air at a temperature of 3°C was supplied from the vortex tube. Experimental data is used for ANOVA (balanced) analysis. The cutting parameters such as feed rate, cutting speed and tool type (coating) are considered as input and the measured thrust force, delamination factor and AE RMS signal are treated as output responses. From ANOVA results, it is observed that the influence of feed rate is more on thrust force as compared to cutting speed. The coefficients of determination (R2) shows good fit between thrust force and cutting parameters and the corresponding confidence levels are above 98% for all cutting environments. Similarly, R2 values of delamination factor and AE RMS signals are above 90% and 96% respectively. The minimum thrust force and torque values are noted as 12.61 N and 0.152 N-m respectively at lower feed rate (10 mm/min) and higher cutting speed (1500 RPM) using TiCN coated drill under chilled air cutting environment. The delamination factor is also low (1.025) under the same cutting conditions of minimum cutting forces. A good correlation exists between the thrust force vs. delamination factor (> 0.85) and the delamination factor vs. AE RMS signal (> 0.80) for the selected cutting environments. The recommended range of RMS voltage is 0.083 to 0.121 volts for producing the delamination free holes on GFRP nanocomposites.

scholarly journals Evaluation of Factors Affecting Delamination, Tensile Strength, Thrust Force and Surface Roughness in Drilling of GFRP

2021 ◽  
Author(s):  
Erol KILICKAP ◽  
Yahya Hışman Celik ◽  
Burak Yenigun
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Gfrp Composites ◽  
Glass Fiber Reinforced Plastic ◽  
Delamination Factor ◽  
Drilling Parameters

Abstract The drilling operation of glass fiber reinforced plastic (GFRP) composites has gained importance because they are used as structural components in many industries such as aerospace and aviation. In the drilling of GFRP composites, some problems such as deformation and fiber breakage occur. Thrust force, delamination, surface quality and cutting temperature are affected by drilling parameters and woven types in the drilling of GFRP composites. At the same time, delamination also affects tensile strength. In this study, the effects of drilling parameters and woven types of GFRP composites on thrust force, surface roughness, delamination factor, and cutting temperature were examined in the drilling of GFRP composites produced in unidirectional (UD), ± 45º and 0°/90º woven types. The effects of drilling parameters and the delamination factor on the tensile strength of the drilled specimen were also investigated. The result of this study indicated that thrust force, delamination factor, and surface roughness increased with increasing cutting speed and feed rate. An increase in feed rate decreased the cutting temperature while an increase in cutting speed increased the cutting temperature. Also, it was found that the delamination had a critical influence on the tensile strength of the GFRP composites.

Experimental Studies on the Influence of Cutting Parameters on Thrust Force and Torque during Drilling of GFRP with SiC Fillers

2010 ◽  
Vol 443 ◽  
pp. 342-346 ◽  
Author(s):  
Mouleeswaran Senthil Kumar ◽  
Vijayan Krishnaraj
Keyword(s):  
Thrust Force ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Gfrp Composites ◽  
Glass Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic ◽  
Twist Drills ◽  
Selection Of

The paper discusses the influence of cutting parameters such as cutting speed, feed rate and point angle on thrust force and torque while drilling of Glass Fiber Reinforced Plastic (GFRP) composites with Silican Carbide (SiC) fillers. The experiments were conducted during the drilling of GFRP with SiC fillers using four standard twist drills of point angles 90º, 100º, 110º and 120º. Conclusions thus drawn are presented and can be useful for the selection of the best cutting parameters.

scholarly journals Optimization of Process Parameters with Minimum Thrust Force and Torque in Drilling Operation Using Taguchi Method

2014 ◽  
Vol 6 ◽  
pp. 925382 ◽  
Author(s):  
Suleyman Neseli
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Machining Process ◽  
Low Thrust ◽  
Taguchi Optimization

This research outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in drilling of AISI 1040 steel. The drilling parameters evaluated are cutting speed, feed rate, and helix angle. Series of experiments are conducted to relate the cutting parameters on the thrust force and torque. L27(313) orthogonal array, signal-to-noise ratio is employed to analyze the influence of these parameters on thrust force and torque during drilling. Analysis of variance (ANOVA) is used to study the effect of process parameters on machining process. The study shows that the Taguchi method is suitable to solve the stated problem with the minimum number of trials. The main objective is to find the important factors and combination of factors that influence the machining process to achieve low thrust force and torque. The analysis of the Taguchi method indicates that the feed rate is the most significant factor affecting the thrust force, while the cutting speed contributes the most to the torque.

scholarly journals Machinability Analysis of Delamination and Thrust Force in Drilling of Pure and Added GFRP Composites

2021 ◽  
Author(s):  
Ali Unuvar ◽  
Osman Öztürk
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Machining Parameters ◽  
Glass Fiber Reinforced ◽  
Drilling Parameters ◽  
Machinability Index ◽  
Parametric Relationships

Abstract The aim of this work is to define the cutting conditions that allow the drilling of added glass fiber reinforced epoxy composite materials by taking into consideration the exit delamination factor, thrust force and the optimum combination of drilling parameters. The experiments were carried out under two cutting parameters such as cutting speed and feed rate for three levels each. Taguchi experimental design is used to reduce the excessive number of experiments. The experiment design was accomplished by application of the statistical analysis of variance (ANOVA). Correlations between cutting speed/feed rate and the various machining parameters were established to optimize cutting conditions. These correlations were found by quadratic regression using response surface methodology (RSM). Multiple regression analysis (MRA) was also employed to establish parametric relationships between the experimental parameters and the machinability outputs consisting of delamination and thrust force. The machinability refers to the relative ease or difficulty under certain cutting conditions. Therefore, it is very important to understand the factors affect the machinability and to evaluate their effects. Machinability of GFRP composites was enquired. It is aimed to evaluate the machinability of these materials. A machinability index has been developed in current study.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Effects of Different Parameters on Delamination Factor of Glass Fiber Reinforced Plastic (GFRP)

2013 ◽  
Vol 3 (2) ◽  
pp. 17-31
Author(s):  
Vikas Sharma ◽  
Vinod Kumar ◽  
Harmesh Kumar
Keyword(s):  
Glass Fiber ◽  
Feed Rate ◽  
Experimental Investigations ◽  
Fiber Reinforced ◽  
Glass Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Delamination Factor ◽  
Glass Fiber Reinforced ◽  
Drill Bits ◽  
Reinforced Plastic

The experimental investigations of the delamination factor of glass fiber reinforced plastic at different cutting parameters are reported in this study. This paper has involved the determination of different factors affecting the hole quality and cause of delamination in a glass fiber reinforced plastic. The various process parameters like different twist drill bits of different materails, different point angle at different speed, feed rate have been taken. The thrust forces and torque values were measured using piezoelectric dynamometer. Mathematical model has been developed for different machining conditions using Minitab software with help of Taguchi design to plan the experiments. The Universal microscope has been used which determines delaminated diameter in GFRP specimens. The finite element method has been applied by using Ansys11.0 software which helped to find out delaminated diameter. It was experimentally observed that for the tungsten carbide and M50 drill bits, the thrust force and torque significant increases on increasing the point angle and feed rate.

Predicting Drilling Forces and Delamination in GFRP Laminates using Fuzzy Logic

2014 ◽  
Vol 1 (2) ◽  
pp. 32-43
Author(s):  
Vikas Dhawan ◽  
Sehijpal Singh ◽  
Inderdeep Singh
Keyword(s):  
Thrust Force ◽  
Cutting Speed ◽  
Fuzzy Rule ◽  
Work Piece ◽  
Fiber Reinforced ◽  
Reinforced Plastics ◽  
Glass Fiber Reinforced ◽  
Drill Diameter ◽  
Solid Carbide ◽  
Experimental Values

Drilling of fiber reinforced plastics is necessary in order to assemble complex/intricate composite products. Drilling induced damage leads to high percentage of part rejection and reduced product efficiency and life. The thrust force and torque have been found to be the important factors influencing damage. In the present research endeavor, an attempt has been made to develop a fuzzy rule based model for predicting thrust force, torque and drilling induced delamination during drilling of glass fiber reinforced epoxy plastics (GFREP). The work piece material, drill geometry, drill diameter, feed and cutting speed have been considered as the five input parameters. Four types of solid carbide drills namely 8 facet, 4 facet, parabolic and jodrill of 4 mm and 8 mm size were used to make holes in UD-GFREP and { (0/90) /0]s GFREP laminates at three different levels of speed and feed. The results of the predictive model have been found to be in good agreement with experimental values.

EXPERIMENTAL STUDIES ON THRUST FORCE AND TORQUE DURING DRILLING OF GLASS FIBER REINFORCED PLASTIC WITH SIC FILLERS

2010 ◽  
Vol 09 (01) ◽  
pp. 63-72 ◽  
Author(s):  
M. SENTHIL KUMAR
Keyword(s):  
Thrust Force ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Gfrp Composites ◽  
Glass Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic ◽  
Influencing Parameters ◽  
Twist Drills

The paper discusses the study on thrust force and torque while drilling GFRP composites with SiC fillers. The input parameters such as cutting speed, feed rate and point angle were varied and influencing parameters such as thrust force and torque were studied. The experimental investigation was made during the drilling of GFRP with SiC fillers using four standard twist drills of point angles 90°, 100°, 110° and 120°.

Surface quality optimization of CFRP plates drilled with standard and step drill bits using TAGUCHI, TOPSIS and AHP method

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Gökhan Sur ◽  
Ömer Erkan
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Ahp Method ◽  
Content Type ◽  
Delamination Factor ◽  
Drill Bits

Purpose Drilling of carbon fiber reinforced plastic (CFRP) composite plates with high surface quality are of great importance for assembly operations. The article aims to optimize the drill geometry and cutting parameters to improve the surface quality of CFRP composite material. In this study, CFRP plates were drilled with uncoated carbide drill bits with standard and step geometry. Thus, the effects of standard and step drill bits on surface quality have been examined comparatively. In addition, optimum output parameters were determined by Taguchi, ANOVA and multiple decision-making methods. Design/methodology/approach Drill bit point angles were selected as 90°, 110° and 130°. In cutting parameters, three different cutting speeds (25, 50 and 75 m/min) and three different feeds (0.1, 0.15 and 0.2 mm/rev) were determined. L18 orthogonal sequence was used with Taguchi experimental design. Three important output parameters affecting the surface quality are determined as thrust force, surface roughness and delamination factor. For each output parameter, the effects of drill geometry and cutting parameters were evaluated. Input parameters affecting output parameters were analyzed using the ANOVA method. Output parameters were estimated by creating regression equations. Weights were determined using the analytic hierarchy process (AHP) method, and multiple output parameters were optimized using technique for order preference by Similarity to An ideal solution (TOPSIS). Findings It has been determined from the experimental results that step drills generate smaller thrust forces than standard drills. However, it has been determined that it creates greater surface roughness and delamination factor. From the Taguchi analysis, the optimum input parameters for Fz step tool geometry, 90° point angle, 75 m/min cutting speed and 0.1 mm/rev feed. For Fd, are standard tool geometry, 90° point angle, 25 m/min cutting speed and 0.1 mm/rev feed and for Ra, are standard tool geometry, 130° point angle, 25 m/min cutting speed and 0.1 mm/rev feed. ANOVA analysis determined that the most important parameter on Fd is the tip angle, with 56.33%. The most important parameter on Ra and Fz was found to be 40.53% and 77.06% tool geometry, respectively. As a result of the optimization with multiple criteria decision-making methods, the test order that gave the best surface quality was found as 4–1-9–5-8–17-2–13-6–16-18–15-11–10-3–12-14. The results of the test number 4, which gives the best surface quality, namely, the thrust force is 91.86 N, the surface roughness is 0.75 µm and the delamination factor is 1.043. As a result of experiment number 14, which gave the worst surface quality, the thrust force was 149.88 N, the surface roughness was 3.03 µm and the delamination factor was 1.163. Practical implications Surface quality is an essential parameter in the drilling of CFRP plates. Cutting tool geometry comes first among the parameters affecting this. Therefore, different cutting tool geometries are preferred. A comparison of these cutting tools is discussed in detail. On the other hand, thrust force, delamination factor and surface roughness, which are the output parameters that determine the surface quality, have been optimized using the TOPSIS and AHP method. In this way, this situation, which seems complicated, is presented in a plain and understandable form. Originality/value In the experiments, cutting tools with different geometries are included. Comparatively, its effects on surface quality were examined. The hole damage mechanism affecting the surface quality is discussed in detail. The results were optimized by evaluating Taguchi, ANOVA, TOPSIS and AHP methods together.

scholarly journals Optimization for drilling process of metal-composite aeronautical structures

2021 ◽  
Vol 28 (1) ◽  
pp. 264-275
Author(s):  
Cristiano Devitte ◽  
Gabriel S. C. Souza ◽  
André J. Souza ◽  
Volnei Tita
Keyword(s):  
Feed Rate ◽  
Composite Laminates ◽  
Thrust Force ◽  
Cutting Speed ◽  
Statistical Design ◽  
Burr Formation ◽  
Drilling Process ◽  
Metal Composite ◽  
Aircraft Manufacturing ◽  
Delamination Factor

Abstract Metal-composite laminates and joints are applied in aircraft manufacturing and maintenance (repairing) using aluminum alloys (AA) and glass fiber-reinforced polymer (GFRP). In these applications, drilling has a prominent place due to its vast application in aeronautical structures’ mechanical joints. Thus, this study presents the influence of uncoated carbide drills (85C, 86C, H10N), cutting speeds (v c = 20, 40, and 60 m min−1), and feed rates (f = 0.05, 0.15, and 0.25 mm rev−1) on delamination factor, thrust force ( F t {F}_{\text{t}} ), and burr formation in dry drilling metal-composite laminates and joints (AA2024/GFRP/AA2024). Experiments were performed, analyzed, and optimized using the Box–Behnken statistical design. Microscopic digital images for delamination evaluation, piezoelectric dynamometer for thrust force acquisition, and burr analysis were considered. The major finding was that the thrust force during drilling depends significantly on the feed rate. Another significant factor was the influence of the drill type (combined or not with feed rate). In fact, it was verified that the feed rate and the drill type were the most significant parameters on the delamination factor, while the feed rate was the most relevant on thrust force. The cutting speed did not affect significantly thrust force and delamination factor at exit ( F da S ) \hspace{.25em}({F}_{{\text{da}}_{\text{S}}}) . However, the combination f × v c was significant in delamination factor at entrance   ( F da E ) \text{ }({F}_{{\text{da}}_{\text{E}}}) . Based on the optimized input parameters, they presented lower values for delamination factors ( F da E = 1.18 {F}_{{\text{da}}_{\text{E}}}=1.18 and F da S = 1.33 {F}_{{\text{da}}_{\text{S}}}=\hspace{.25em}1.33 ) and thrust force ( F t = 67.3 N {F}_{\text{t}}=67.3\hspace{.5em}\text{N} ). These values were obtained by drilling the metal-composite laminates with 85C-tool, 0.05 mm rev−1 feed rate, and 20 m min−1 cutting speed. However, the burrs at the hole output of AA2024 were considered unsatisfactory for this specific condition, which implies additional investigation.

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