Optimization of Drilling Parameters on Alkaline Treated Jute fiber Sandwich Material

The present work efforts to determine CNC drilling performance and optimization of drilling parameters during drilling of treated JFRPPU-foam sandwich structures. In this drilling operation the ensuing process performance structures viz thrust, torque and delamination factor for entry and exit hole have been recognized. The effort has been made to regulate the optimal drilling parameters set. Taguchi method employed for design of experiment. The effects of parameters process such as composite geometry type, feed rate, drill speed, and drill size varied each at three different levels. In this experimentation sandwich structures L27 orthogonal array is used. A nonlinear regression model is measured and formulates the function based on the drilling parameters and fitness function. The result shows the minimization thrust force, delamination of hole drill diameter and feed rate more effect than the speed. TAN coated carbide twist drilled hole gives the result more percentage to reduce the hole wall delamination.

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Performance Analysis of Multi-Spindle Drilling of Al2024 with TiN and TiCN Coated Drills Using Experimental and Artificial Neural Networks Technique

Applied Sciences ◽

10.3390/app10238633 ◽

2020 ◽

Vol 10 (23) ◽

pp. 8633

Author(s):

Muhammad Aamir ◽

Majid Tolouei-Rad ◽

Ana Vafadar ◽

Muhammad Nouman Amjad Raja ◽

Khaled Giasin

Keyword(s):

Surface Roughness ◽

Thrust Force ◽

Drilling Process ◽

Hole Quality ◽

Drilling Performance ◽

Coated Tools ◽

Drilling Parameters ◽

Increase Productivity ◽

Coated Carbide ◽

Multiple Holes

Multi-spindle drilling simultaneously produces multiple holes to save time and increase productivity. The assessment of hole quality is important in any drilling process and is influenced by characteristics of the cutting tool, drilling parameters and machine capacity. This study investigates the drilling performance of uncoated carbide, and coated carbide (TiN and TiCN) drills when machining Al2024 aluminium alloy. Thrust force and characteristics of hole quality, such as the presence of burrs and surface roughness, were evaluated. The results show that the uncoated carbide drills performed better than the TiN and TiCN coated tools at low spindle speeds, while TiCN coated drills produced better hole quality at higher spindle speeds. The TiN coated drills gave the highest thrust force and poorest hole quality when compared with the uncoated carbide and TiCN coated carbide drills. Additionally, a multi-layer perceptron neural network model was developed, which could be useful for industries and manufacturing engineers for predicting the surface roughness in multi-hole simultaneous drilling processes.

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Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack

Journal of Composites Science ◽

10.3390/jcs5070189 ◽

2021 ◽

Vol 5 (7) ◽

pp. 189

Author(s):

Muhammad Hafiz Hassan ◽

Jamaluddin Abdullah ◽

Gérald Franz ◽

Chim Yi Shen ◽

Reza Mahmoodian

Keyword(s):

Feed Rate ◽

Thrust Force ◽

Critical Dimension ◽

Helix Angle ◽

Single Shot ◽

Twist Drill ◽

Hole Quality ◽

Drilling Parameters ◽

Industry Practice ◽

Maximum Thrust

Drilling two different materials in a layer, or stack-up, is being practiced widely in the aerospace industry to minimize critical dimension mismatch and error in the subsequent assembly process, but the compatibility of the drill to compensate the widely differing properties of composite is still a major challenge to the industry. In this paper, the effect of customized twist drill geometry and drilling parameters are being investigated based on the thrust force signature generated during the drilling of CFRP/Al7075-T6. Based on ANOVA, it is found that the maximum thrust force for both CFRP and Al7075-T6 are highly dependent on the feed rate. Through the analysis of maximum thrust force, supported by hole diameter error, hole surface roughness, and chip formation, it is found that the optimum tool parameters selection includes a helix angle of 30°, primary clearance angle of 6°, point angle of 130°, chisel edge angle of 30°, speed of 2600 rev/min and feed rate of 0.05 mm/rev. The optimum parameters obtained in this study are benchmarked against existing industry practice of the capability to produce higher hole quality and efficiency, which is set at 2600 rev/min for speed and 0.1 mm/rev for feed rate.

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Effects of Cutting Parameters on Tool Wear and Thrust Force in Drilling Nickel-Titanium (NiTi) Alloys Using Coated and Uncoated Carbide Tools

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.791.111 ◽

2018 ◽

Vol 791 ◽

pp. 111-115 ◽

Cited By ~ 1

Author(s):

Rosmahidayu Rosnan ◽

Azwan Iskandar Azmi ◽

Muhamad Nasir Murad

Keyword(s):

Wear Resistance ◽

Tool Wear ◽

Thrust Force ◽

Cutting Parameters ◽

Nickel Titanium ◽

Burr Formation ◽

Machining Processes ◽

Drilling Parameters ◽

Mechanical Machining ◽

Coated Carbide

The difficulties of machining nickel-titanium alloys are due to their high ductility and super-elasticity, strong strain-hardening, and excellent wear resistance. These characteristics lead to poor chip breakability, high cutting forces, rapid and aggressive tool-wear, as well as excessive burr formation during mechanical machining processes. The present study addresses these issues by evaluating the effects of drilling parameters and drill bit coatings on the growth of tool wear and development of the drilling thrust force. The findings from this research indicate that the TiAlN coated carbide drill was found to significantly improve the wear resistance of the cutting tool. Likewise, the results of thrust force development are consistent with the trends of tool wear growth for all of the tested carbide drills.

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Optimasi Multirespon Gaya Tekan Dan Momen Torsi Pada Penggurdian Material Komposit Glass Fiber Reinforce Polymer (Gfrp) yang Ditumpuk Dengan Material Stainless Steel (SS) Menggunakan Metode Algoritma Genetika

Manutech : Jurnal Teknologi Manufaktur ◽

10.33504/manutech.v9i01.10 ◽

2019 ◽

Vol 9 (01) ◽

pp. 1-5

Author(s):

Angga Sateria

Keyword(s):

Stainless Steel ◽

Glass Fiber ◽

Process Parameters ◽

Feed Rate ◽

Thrust Force ◽

Spindle Speed ◽

Quality Characteristic ◽

Drilling Process ◽

Glass Fiber Reinforced ◽

Different Levels

Glass fiber reinforced polymer (GFRP)-stainless steel stacks used in the aircraft structural components. The assembly process of this components requires mechanical joining using bolt and nut. The drilling process is commonly used for producing hole to position the bolt correctly. Thrust force and torque are responses that used to evaluate the performance of drilling process. The quality characteristic of these responses are “smaller-is-better.” The aim of this experiment is to identify the combination of process parameters for achieving required multiple performance characteristics in drilling process of GFRP-stainless steel stacks materials. The three important process parameters, i.e., point angle, spindle speed, and feed rate were used as input parameters. Point angle was set at two different levels, whilethe other two were set at three different levels. Hence, a 2 x 3 x 3 full factorial was used as designexperiments. The experiments were replicated two times. The optimization was conducted by using genetic algorithm method. The minimum thrust force and torque could be obtained by using point angle, spindle speed and feed rate of 118o, 2383 rpm, 62 mm/min respectively.

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Machinability of drilling T700/LT-03A carbon fiber reinforced plastic (CFRP) composite laminates using candle stick drill and multi-facet drill

International Journal of Modern Physics B ◽

10.1142/s0217979215400317 ◽

2015 ◽

Vol 29 (10n11) ◽

pp. 1540031 ◽

Cited By ~ 3

Author(s):

Cheng-Dong Wang ◽

Kun-Xian Qiu ◽

Ming Chen ◽

Xiao-Jiang Cai

Keyword(s):

Carbon Fiber ◽

Feed Rate ◽

Composite Laminates ◽

Thrust Force ◽

Spindle Speed ◽

Carbon Fiber Reinforced Plastic ◽

Fiber Reinforced Plastic ◽

Reinforced Plastic ◽

Drilling Parameters ◽

Cfrp Composite

Carbon Fiber Reinforced Plastic (CFRP) composite laminates are widely used in aerospace and aircraft structural components due to their superior properties. However, they are regarded as difficult-to-cut materials because of bad surface quality and low productivity. Drilling is the most common hole making process for CFRP composite laminates and drilling induced delamination damage usually occurs severely at the exit side of drilling holes, which strongly deteriorate holes quality. In this work, the candle stick drill and multi-facet drill are employed to evaluate the machinability of drilling T700/LT-03A CFRP composite laminates in terms of thrust force, delamination, holes diameter and holes surface roughness. S/N ratio is used to characterize the thrust force while an ellipse-shaped delamination model is established to quantitatively analyze the delamination. The best combination of drilling parameters are determined by full consideration of S/N ratios of thrust force and the delamination. The results indicate that candle stick drill will induce the unexpected ellipse-shaped delamination even at its best drilling parameters of spindle speed of 10,000 rpm and feed rate of 0.004 mm/tooth. However, the multi-facet drill cutting at the relative lower feed rate of 0.004 mm/tooth and lower spindle speed of 6000 rpm can effectively prevent the delamination. Comprehensively, holes quality obtained by multi-facet drill is much more superior to those obtained by candle stick drill.

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Drilling of Carbon Fibre Composites: A Review

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.903.3 ◽

2014 ◽

Vol 903 ◽

pp. 3-8 ◽

Cited By ~ 2

Author(s):

Aishah Najiah Dahnel ◽

Stuart Barnes ◽

Pipat Bhudwannachai

Keyword(s):

Tool Wear ◽

Carbon Fibre ◽

Feed Rate ◽

Cutting Tool ◽

Thrust Force ◽

Fibre Composite ◽

Cutting Speed ◽

Heterogeneous Structure ◽

Drilling Performance ◽

Carbon Fibre Composites

Machining of Carbon Fibre Composite (CFC), particularly drilling is frequently employed in many industries especially when dealing with joining, assembly and structural repair of the parts. This paper summarizes the properties of the CFC as well as the appropriate material and geometry of the cutting tool that should be used when drilling of the CFC in order to optimize the drilling performance. In addition, this work also presents the literature review on the relationship between cutting speed, feed rate, tool wear, thrust force and damage of the drilled CFC. The nature and heterogeneous structure of CFC often resulted in difficulty during their machining in terms of rapid tool wear and high thrust force. As a result, this always results in the damage of the drilled parts. Furthermore, higher cutting speed and lower feed rate are also recognized as significant factors which contribute to rapid wear of the cutting tool. Therefore, the use of tungsten carbide cutting tools, cutting fluids and cryogenic machining is seen to be a practical technique in optimizing the drilling performance involving CFC. In general, this work intends to provide a basic guideline and understanding regarding drilling of the CFC.

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Delamination Analysis in Drilling Carbon Fiber-Reinforced Composites

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.697.62 ◽

2014 ◽

Vol 697 ◽

pp. 62-66

Author(s):

Hong Fei Wang ◽

Hua Zhou Li ◽

Long Sheng Lu ◽

Ying Xi Xie ◽

Yu Xiao

Keyword(s):

Carbon Fiber ◽

Feed Rate ◽

Thrust Force ◽

Industrial Applications ◽

Spindle Speed ◽

Fiber Reinforced ◽

Delamination Factor ◽

Cfrp Composites ◽

Drill Diameter ◽

Carbon Fiber Reinforced

Due to its excellent performance, carbon fiber-reinforced plastics (CFRP) have been widely applied in industrial applications. The phenomenon of delamination can readily occur when drilling CFRP composites, which affects the quality of drilling holes. To effectively control the generation of processing defects, this paper focused on the analysis of the thrust force and the delamination factor. The delamination analysis was performed using graphs of the spindle speed, feed rate and drill diameter as independent parameters. The results suggest that there was a positive correlation between the delamination factor Fd and the thrust force Fz. The delamination factor decreases with increases in the spindle speed and increases with increases in the feed rate or with increases in the drill diameter. Based on the experimental data, this paper established a formula model of the delamination factor Fd, which would promote the further study of drilling CFRP composites.

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

10.21203/rs.3.rs-207947/v1 ◽

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.

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Experimental Investigation of Thrust Force, Delamination and Surface Roughness in Drilling Hybrid Structural Composites

Materials ◽

10.3390/ma14164468 ◽

2021 ◽

Vol 14 (16) ◽

pp. 4468

Author(s):

Vigneshwaran Shanmugam ◽

Uthayakumar Marimuthu ◽

Sundarakannan Rajendran ◽

Arumugaprabu Veerasimman ◽

Adamkhan Mahaboob Basha ◽

...

Keyword(s):

Feed Rate ◽

Thrust Force ◽

Hybrid Composites ◽

Cutting Speed ◽

Burr Formation ◽

Sisal Fibre ◽

Drilling Performance ◽

Fibre Composites ◽

Structural Applications ◽

Polyester Matrix

Filled hybrid composites are widely used in various structural applications where machining is critical. Hence, it is essential to understand the performance of the fibre composites’ machining behaviour. As such, a new hybrid structural composite was fabricated with redmud as filler and sisal fibre as reinforcement in polyester matrix. The composite was then tested for its drilling performance. A comprehensive drilling experiment was conducted using Taguchi L27 orthogonal array. The effect of the drill tool point angle, the cutting speed, the feed rate on thrust force, delamination, and burr formation were analysed for producing quality holes. The significance of each parameter was analysed, and the experimental outcomes revealed some important findings in the context of the drilling behaviour of sisal fibre/polyester composites with redmud as a filler. Spindle speed contributed 39% in affecting the thrust force, while the feed rate had the maximum influence of ca. 38% in affecting delamination.

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Characterization of Thrust Force, Temperature, Chip Morphology and Power in Ultrasonic-assisted Drilling of Aluminium 6061

10.21203/rs.3.rs-441144/v1 ◽

2021 ◽

Author(s):

Amin Moghaddas

Keyword(s):

Feed Rate ◽

Thrust Force ◽

Chip Morphology ◽

High Amplitude ◽

Spindle Speed ◽

Drilling Parameters ◽

Out Of Sample ◽

Ultrasonic Assisted ◽

Turning Center ◽

Chip Size

Abstract In this study, a special resolution V design and Response surface methodology (RSM) were used to characterize the ultrasonic-assisted drilling (UAD) process of Aluminum 6061. This characterization was done through developing mathematical models to study the effect of ultrasonic and drilling parameters including spindle speed, feed rate and amplitude on thrust force, temperature, chip morphology and power. The tests were done using an industrially hardened non-rotating UAD system mounted in a CNC turning center. The analysis of variance (ANOVA) was used to find significant parameters of thrust force, temperature, chip morphology and power. Then, for all responses, the optimum drilling parameters that provide desired solutions for all responses were obtained. This was followed by out-of-sample testing to verify the accuracy of the developed models. The results of this study showed that in UAD of aluminum, the minimum values of thrust force and chip size were obtained at low spindle speed, low feed rate and high amplitude. The results also showed that amplitude was not a significant parameter affecting the tool temperature and cannot be used to analyze the effect of ultrasonic vibrations on generated heat during UAD. Instead, the interaction of amplitude and feed rate was significant and should be considered in the analysis. Finally, minimum consumed power, specially at higher amplitudes, can be obtained using high spindle speed and low feed rate.

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