scholarly journals Heat-Affected Zone and Mechanical Analysis of GFRP Composites with Different Thicknesses in Drilling Processes

Polymers ◽  
2021 ◽  
Vol 13 (14) ◽  
pp. 2246
Author(s):  
Usama A. Khashaba ◽  
Mohamed S. Abd-Elwahed ◽  
Ismai Najjar ◽  
Ammar Melaibari ◽  
Khaled I. Ahmed ◽  
...  
Keyword(s):  
Thrust Force ◽  
Cutting Speed ◽  
Image Processing Technique ◽  
Maximum Temperature ◽  
Cutting Condition ◽  
Drilling Process ◽  
Feed Speed ◽  
Cnc Machine ◽  
Gfrp Composites ◽  
Ir Camera

This article presents a comprehensive thermomechanical analysis and failure assessment in the drilling of glass fiber-reinforced polymer (GFRP) composites with different thicknesses using a CNC machine and cemented carbide drill with a diameter of 6 mm and point angles of ϕ = 118°. The temperature distribution through drilling was measured using two techniques. The first technique was based on contactless measurements using an IR Fluke camera. The second was based on contact measurements using two thermocouples inserted inside the drill bit. A Kistler dynamometer was used to measure the cutting forces. The delamination factors at the hole exit and hole entry were quantified by using the image processing technique. Multi-variable regression analysis and surface plots were performed to illustrate the significant coefficients and contribution of the machining variables (i.e., feed, speed, and laminate thickness) on machinability parameters (i.e., the thrust force, torque, temperatures, and delamination). It is concluded that the cutting time, as a function of machining variables, has significant control over the induced temperature and, thus, the force, torque, and delamination factor in drilling GFRP composites. The maximum temperature recorded by the IR camera is lower than that of the instrumented drill because the IR camera cannot directly measure the tool–work interaction zone during the drilling process. At the same cutting condition, it is observed that by increasing the thickness of the specimen, the temperature increased. Increasing the thickness from 2.6 to 7.7 had a significant effect on the heat distribution of the HAZ. At a smaller thickness, increasing the cutting speed from 400 to 1600 rpm decreased the maximum thrust force by 15%. The push-out delaminations of the GFRP laminate were accompanied by edge chipping, spalling, and uncut fibers, which were higher than those of the peel-up delaminations.

scholarly journals Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 386 ◽  
Author(s):  
Krzysztof Szwajka ◽  
Joanna Zielińska-Szwajka ◽  
Tomasz Trzepiecinski
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Medium Density Fiberboard ◽  
Cutting Speed ◽  
Piezoelectric Sensor ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Aesthetic Appearance

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc., compared to wood. Medium density fiberboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests, three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analyzed using a multi-factorial analysis of variance (ANOVA).

scholarly journals Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN

2019 ◽  
Author(s):  
Krzysztof Szwajka ◽  
Joanna Zielńska-Szwajka ◽  
Tomasz Trzepieciński
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Speed ◽  
Piezoelectric Sensor ◽  
Solid Wood ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Aesthetic Appearance

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc. compared to wood. Medium density fibreboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analysed using a multi-factorial analysis of variance (ANOVA).

Fuzzy Logic in Hole Drilling of Composites

1994 ◽  
Author(s):  
Aditya Thadani ◽  
Athamaram H. Soni
Keyword(s):  
Fuzzy Logic ◽  
Fuzzy Logic Controller ◽  
Thrust Force ◽  
Cutting Speed ◽  
Research Data ◽  
Theoretical Research ◽  
Hole Drilling ◽  
Tool Geometry ◽  
Drilling Process ◽  
And Control

Abstract Experimental and theoretical research data was utilized in building a Fuzzy Logic Controller model applied to simulate the drilling process of composite materials. The objective is to have a better understanding and control of delamination of composites during the drilling process and at the same time to improve the hole finish by controlling fraying and splintering. By controlling the main issues in the drilling process such as feed rate, cutting speed, thrust force, and torque generated in addition to the tool geometry, it is possible to optimize the drilling process avoiding the conventionally encountered problems.

Effect of Milling Speed and Feed on Surface Residual Stress of 7050-T7451 Aluminum Alloy

2012 ◽  
Vol 499 ◽  
pp. 217-222 ◽  
Author(s):  
C. Li ◽  
Yi Wan ◽  
R.R. Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Speed ◽  
Diffraction Method ◽  
Cutting Condition ◽  
Feed Speed ◽  
X Ray Diffraction ◽  
Surface Residual Stress ◽  
Orthogonal Direction ◽  
Machined Surface

The residual stress in the milling of 7050-T7451 aluminum alloy was measured using X-ray diffraction method in which Psi-oscillation, Phi-oscillation and peak fit were adopted. Cutting speed and feed are main variables which were considered in this study. The results show that compressive residual stresses are generated in surface for the down milling generally, which is mainly due to burnishing effect between the tools flank face and the machined surface. In feed and its orthogonal direction, the effect of cutting speed and feed speed on residual stress is similar. Therefore, required residual stress can be achieved by controlling the cutting condition such as cutting speed, feed speed etc.

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°.

Finite Element Method Simulation of Drilling Process on Metal-Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 372-375
Author(s):  
H.L. Zhang ◽  
Jin Chen
Keyword(s):  
Finite Element ◽  
Feed Rate ◽  
Shear Failure ◽  
Thrust Force ◽  
Equivalent Stress ◽  
Damage Model ◽  
Cutting Speed ◽  
Finite Element Method Simulation ◽  
Drilling Process ◽  
Machining Processes

Drilling is one of the complex machining processes, which has been widely applied in the manufacturing area. In this paper, a 3D coupled thermo-mechanical finite element model was used for simulating the thrust force, torque and von Mises equivalent stress at different cutting conditions. The J-C damage model (shear failure) was used in conjunction with the J-C plasticity model, as well as the continuous adaptive remeshing technical. The results show that the thrust force and torque increase with the increasing of the cutting speed and feed rate, and the influence of the feed rate is more obviously.

A Study of Surface Integrity when Machining Refractory Titanium Alloys

2009 ◽  
Vol 83-86 ◽  
pp. 1059-1068 ◽  
Author(s):  
Armansyah Ginting ◽  
Mohammed Nouari ◽  
Nadhir Lebaal
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Surface Integrity ◽  
Bulk Material ◽  
Cutting Speed ◽  
Cutting Condition ◽  
Feed Speed ◽  
Machined Surface ◽  
Feed Mark ◽  
Coated Carbide

In this paper, the surface integrity is studied when machining the aeronautical titanium alloys. Surface roughness, lay, defects, microhardness and microstructure alterations are studied. The result of surface roughness judges that the CVD-coated carbide fails to produce better Ra value than the uncoated. Lay is characterized by cutting speed and feed speed directions. Feed mark, tearing surface, chip layer formation as built up layer (BUL), and deposited microchip are the defects. Microhardness is altered down to 350 microns beneath the machined surface. The first 50 microns is the soft sub-surface caused by thermal softening in ageing process. Microstructure alteration is observed in this sub-surface. Down to 200 microns is the hard sub-surface caused by the cyclic internal work hardening and then it is gradually decreasing to the bulk material hardness. It is concluded that dry machining titanium alloy is possible using uncoated carbide with cutting condition limited to finish or semi-finish for minimizing surface integrity alteration.

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.

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.

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