Effects of Cutting Parameters on Hole Integrity when Drilling GFRP and HFRP Composites

2013 ◽  
Vol 845 ◽  
pp. 960-965
Author(s):  
Mohd Azuwan Maoinser ◽  
Faiz Ahmad ◽  
Safian Sharif
Keyword(s):  
Composite Materials ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Matrix Cracking ◽  
Fiber Reinforced ◽  
Damage Factor ◽  
Electron Microscopic ◽  
Pull Out

The demand for mechanical fastening in composite materials is increasing due to their potential in large assemblies, aerospace and automotive industries. In practice, small components are integrated into large assemblies drilling holes in composite materials. Drilling defect free holes in composite presents many challenges during part assembly and services. This study presents the effects of cutting parameters used for drilling holes in glass fiber reinforced polymeric (GFRP) composites and hybrid fiber reinforced polymeric (HFRP) composites. Both the composites plates of 3 mm thickness were fabricated using a hand lay-up technique for the purpose of evaluating the effects of parameters on the quality of drilled holes. The holes were drilled using a 5 mm solid carbide twist drill at different spindle speed and feed rate. The quality of holes was assessed with respect to damage factor (Fd) and surface roughness (Ra) of the drilled holes. Results showed that the HFRP composite experienced lower damage factor (Fd) as compared to GFRP composite at lower feed rate or spindle speed. Scanning electron microscopic (SEM) examination revealed that the occurrence of delamination, fiber pull-out and matrix cracking was accelerated in the drilled holes at high spindle speed and feed rate.

Evaluation of Delamination in Drilling Rice Husk Reinforced Polyester Composites

2012 ◽  
Vol 232 ◽  
pp. 106-110 ◽  
Author(s):  
S.A. Syed Azuan ◽  
J.M. Juraidi ◽  
Wan Mansor Wan Muhamad
Keyword(s):  
Composite Materials ◽  
Rice Husk ◽  
Feed Rate ◽  
Spindle Speed ◽  
Fiber Reinforced Polymer ◽  
Drilling Process ◽  
Fiber Reinforced ◽  
End Mill ◽  
Reinforced Polymer ◽  
Polyester Composites

Delamination is recognized as one of the most critical defects that can result from the machining composites. Delamination has been a major form of failure in drilled composite materials due to the composites lack of strength in the drilling direction, which results in poor surface finish, reduction in bearing strength, reduction in structural integrity and ultimately poor performance of the composite. Currently, most of the major research reported delamination address specific of machining fiber glass, graphite fiber or carbon fiber reinforced polymer composites. It is not yet clear how different drilling parameters affect the machinability of natural fiber reinforced polymer composite materials and quality of drilled holes. This paper report the investigation in drilling holes on natural fibre reinforced polyester composites and evaluate its hole quality by measuring delamination. Three different type of drill: twist 118o drill, brad drill and end mill were used. Drilling process is carried out for three spindle speed (1500 rpm, 2000 rpm and 2500 rpm) and three feed rate (0.1 mm/rev, 0.15 mm/rev and 0.2 mm/rev). Brad drill experienced higher delamination values compared to twist and end mill. Increasing of feed rate and spindle speed also caused a relevant increase in the delamination values. It is found that Rice husk reinforced polyester composites delamination value is lower when compared to the glass fiber reinforced polymer.

scholarly journals Study on Surface Roughness in Micro Milling of Single Crystal Materials

2019 ◽  
Vol 1 (1) ◽  
Author(s):  
Qi Gao ◽  
Po Jin ◽  
Guangyan Guo
Keyword(s):  
Surface Roughness ◽  
Single Crystal ◽  
Surface Quality ◽  
Feed Rate ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Micro Milling ◽  
Cemented Carbide Tool

Micro milling is a machining method of high precision and efficiency for micro components and features. In order to study the surface quality of single crystal materials in micro milling, the two-edged cemented carbide tool milling cutter with 0.4 mm diameter was used, and the orthogonal experiment was completed on the micro-milling of single crystal aluminum material. Through the analysis of statistical results, the primary and secondary factor which impacting on surface quality were found as follows: spindle speed, feed rate, milling depth. The ideal combination of optimized process parameters were obtained, when the spindle speed was 36000 r/min, the milling depth was 10 μm, the feed rate was 80 μm/s, which made the milling surface roughness is 0.782 μm and minimal. Single crystal materials removal mechanism were revealed, and the influence of cutting parameters on micro-milling surface were discussed, the reason of tool wear was analyzed. Those provide a certain theoretical and experimental basis for micro milling of single crystal materials.

scholarly journals Effect of Tool Wear on Quality of Carbon Fiber Reinforced Polymer Laminate during Edge Trimming

2013 ◽  
Vol 325-326 ◽  
pp. 34-39 ◽  
Author(s):  
Hossein Hamedanianpour ◽  
Jean François Chatelain
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Tool Wear ◽  
Matrix Cracking ◽  
Fiber Reinforced ◽  
Pull Out ◽  
Carbon Fiber Reinforced ◽  
Coated Carbide ◽  
Cutting Speeds

Polymer matrix composites, particularly carbon fiber reinforced polymers (CFRPs) are widely used in various high technology industries, including aerospace, automotive and wind energy. Normally, when CFRPs are cured to near net shape, finishing operations such as trimming, milling or drilling are used to remove excess materials. The quality of these finishing operations is highly crucial at the level of final assembly. The present research aims to study the effect of cutting tool wear on the resulting quality for the trimming process of high performance CFRP laminates, in the aerospace field. In terms of quality parameters, the study focuses on surface roughness and material integrity (uncut fibers, fiber pull-out, delamination or thermal damage of the matrix), which could jeopardize the mechanical performance of the components. In this study, a 3/8 inch diameter CVD diamond coated carbide tool with six straight flutes was used to trim 24-ply carbon fiber laminates. Cutting speeds ranging from 200 m/min to 400 m/min and feed rates ranging from 1524 mm/min to 4064 mm/min were used in the experiments. The results obtained using a scanning electron microscope (SEM) showed increasing defect rates with increased tool wear. The worst surface integrity, including matrix cracking, fiber pull-out and empty holes, was also observed for plies oriented at -45 degrees. For the surface finish, it was observed that for the studied cutting length ranges, an increase in tool wear resulted in a decrease in surface roughness. Regarding tool wear, a lower rate was observed at lower feed rates and higher cutting speeds, while a higher tool wear rate was observed at intermediate values of our feed rate and cutting speed ranges.

scholarly journals Investigation of Surface Quality for Minor Scale Diameter of Biodegradable Magnesium Alloys during the Turning Process Using a Different Tool Nose Radius

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1174
Author(s):  
Sophal Hai ◽  
Hwa-Chul Jung ◽  
Won-Hyun Shim ◽  
Hyung-Gon Shin
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Turning Process ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Nose Radius

The main objective of the study is to analyze the various cutting parameters to investigate the surface quality of the minor scale diameter of magnesium alloy in the dry turning process using a different tool nose radius (r). The surface roughness (Ra) was gauged, and micro-images produced by scanning electron microscopy (SEM) were reviewed to evaluate the machined surface topography. The analysis of variance (ANOVA), linear regression model and signal-to-noise (S/N) ratio were applied to investigate and optimize the experimental conditions for surface roughness. The study results imply that the feed rate and tool nose radius significantly affected the surface quality, but the spindle speed did not. The linear regression model is valid to forecast the surface roughness. The cutting parameters for optimum surface quality are a combination of a spindle speed of 710 rpm, a feed rate of 0.052 mm/rev and a tool nose radius of 1.2 mm. The machined surface topography contains the feed marks, micro-voids, material side and material debris, but they become smaller and decrease at a lower feed rate, larger tool nose radius and higher spindle speed. These results show the good surface quality of magnesium alloys in a dry turning process, which could be applied in implant, orthopedic and trauma surgery.

scholarly journals Optimization of machining parameters in drilling hybrid sisal-cotton fiber reinforced polyester composites

2022 ◽  
Vol 9 (1) ◽  
pp. 119-134
Author(s):  
Nurhusien Hassen Mohammed ◽  
◽  
Desalegn Wogaso Wolla
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Hybrid Composite ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Fiber Reinforced ◽  
Roundness Error ◽  
Pull Out ◽  
Drill Diameter

<abstract> <p>Machining natural fiber reinforced polymer composite materials is one of most challenging tasks due to the material's anisotropic property, non-homogeneous structure and abrasive nature of fibers. Commonly, conventional machining of composites leads to delamination, inter-laminar cracks, fiber pull out, poor surface finish and wear of cutting tool. However, these challenges can be significantly reduced by using proper machining conditions. Thus, this research aims at optimizing machining parameters in drilling hybrid sisal-cotton fibers reinforced polyester composite for better machining performance characteristics namely better hole roundness accuracy and surface finish using Taguchi method. The effect of machining parameters including spindle speed, feed rate and drill diameter on drill hole accuracy (roundness error) and surface-roughness of the hybrid composite are evaluated. Series of experiments based on Taguchi's L<sub>16</sub> orthogonal array were performed using different ranges of machining parameters namely spindle speed (600,900, 1200, 1600 rpm), feed rate (10, 15, 20, 25 mm/min) and drill diameter (6, 7, 8, 10 mm). Hole roundness error and surface-roughness are determined using ABC digital caliper and Zeta 20 profilometer, respectively. Optimum machining condition for drilling hybrid composite material (speed: 1600 rpm, feed rate: 25 mm/min and drill diameter: 6 mm) is determined, and the results are verified by conducting confirmation test which proves that the results are reliable.</p> </abstract>

Prediction of Surface Roughness and Optimization of Cutting Parameters in CNC Turning of Rotational Features

2020 ◽  
Vol 38 (8A) ◽  
pp. 1143-1153
Author(s):  
Yousif K. Shounia ◽  
Tahseen F. Abbas ◽  
Raed R. Shwaish
Keyword(s):  
Surface Roughness ◽  
Linear Regression ◽  
Regression Model ◽  
Linear Regression Model ◽  
Feed Rate ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Non Linear ◽  
Optimization Of Cutting Parameters

This research presents a model for prediction surface roughness in terms of process parameters in turning aluminum alloy 1200. The geometry to be machined has four rotational features: straight, taper, convex and concave, while a design of experiments was created through the Taguchi L25 orthogonal array experiments in minitab17 three factors with five Levels depth of cut (0.04, 0.06, 0.08, 0.10 and 0.12) mm, spindle speed (1200, 1400, 1600, 1800 and 2000) r.p.m and feed rate (60, 70, 80, 90 and 100) mm/min. A multiple non-linear regression model has been used which is a set of statistical extrapolation processes to estimate the relationships input variables and output which the surface roughness which prediction outside the range of the data. According to the non-linear regression model, the optimum surface roughness can be obtained at 1800 rpm of spindle speed, feed-rate of 80 mm/min and depth of cut 0.04 mm then the best surface roughness comes out to be 0.04 μm at tapper feature at depth of cut 0.01 mm and same spindle speed and feed rate pervious which gives the error of 3.23% at evolution equation.

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.

scholarly journals Mechanical Behavior of Fiber-Reinforced SiC/RBSN Ceramic Matrix Composites: Theory and Experiment

1993 ◽  
Vol 115 (1) ◽  
pp. 91-102 ◽  
Author(s):  
A. Chulya ◽  
J. P. Gyekenyesi ◽  
R. T. Bhatt
Keyword(s):  
Mechanical Behavior ◽  
Ceramic Matrix Composites ◽  
In Situ Monitoring ◽  
Matrix Cracking ◽  
Test Problems ◽  
Interface Debonding ◽  
Failure Behavior ◽  
Fiber Reinforced ◽  
History Effects ◽  
Pull Out

The mechanical behavior of continuous fiber-reinforced SiC/RBSN composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE techniques throughout the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to the fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorporating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytic predictions.

Drilling Force and Chip Morphology in Drilling of PCB Supported Hole

2011 ◽  
Vol 188 ◽  
pp. 429-434 ◽  
Author(s):  
L.P. Yang ◽  
Li Xin Huang ◽  
Cheng Yong Wang ◽  
L.J. Zheng ◽  
Ping Ma ◽  
...  
Keyword(s):  
Feed Rate ◽  
Printed Circuit Board ◽  
Thrust Force ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Circuit Board ◽  
Drilling Process ◽  
Drilling Force ◽  
Drill Bits

Supported holes of Printed circuit board (PCB) are drilled with two different drill bits. Drilling force (thrust force and torque) and chip morphology are examined at different cutting parameters, and the effects of the two drills are discussed. The results indicate that the drilling force and chip morphology are affected by the feed rate, spindle speed and drill shape. Thrust force increases with the increasing feed rate, and decreases with the increasing spindle speed. Optimization of drill geometry can reduce the thrust force significantly, and is effective in chip breaking which can improve the chip evacuation during the drilling process.

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