Investigation on Surface Roughness of Drilled Holes in Nanoparticle Filled Polymer Matrix Composites

2021 ◽  
Vol 105 ◽  
pp. 68-76
Author(s):  
R. Pramod ◽  
S. Basavarajappa ◽  
G.B. Veeresh Kumar
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Polymer Matrix Composites ◽  
Spindle Speed ◽  
Machining Parameters ◽  
Matrix Composites ◽  
The Matrix ◽  
Experimental Values ◽  
Tool Diameter ◽  
Drill Tool

The utilization of nanoparticle filled composite materials in many different engineering fields has undergone a tremendous increase. Accordingly, the need for accurate machining of composites has increased enormously. In the present study, an attempt has been made to assess the factors influencing surface roughness on the machining of nanocomposites and base composites. The Taguchi L16 experimental design concept has been used for experimentation. The drilling experiments were conducted considering spindle speed, drill tool diameter, and feed rate as machining parameters. The empirical model was developed based on the input parameters. Analysis of Variance (ANOVA) established the relation between predicted and experimental values. The regression model was found to be within the level of confidence with greater accuracy indicated by R2 value. The addition of Nanoclay and Graphene as fillers in the matrix improved the surface roughness of the hole. Feed rate and spindle speed were found to be the significant factors of machining and Graphene reinforced composites had better surface finish.

scholarly journals The influence of machining parameters on surface roughness of MDF in milling operation

BioResources ◽  
2019 ◽  
Vol 14 (2) ◽  
pp. 3266-3277
Author(s):  
Ümmü K. İşleyen ◽  
Mehmet Karamanoğlu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Medium Density Fiberboard ◽  
Spindle Speed ◽  
Numerical Control ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Operation ◽  
Four Levels ◽  
Tool Diameter

This paper examined the effect of machining parameters on surface roughness of medium density fiberboard (MDF) machined using a computer numerical control (CNC) router. The machining parameters such as spindle speed, feed rate, depth of cut, and tool diameter were examined for milling. The experiments were conducted at two levels of spindle speeds, four levels of feed rates, two levels of tool diameters, and two levels of axial depths of cut. The surface roughness values of MDF grooved by CNC were measured with stylus-type equipment. Statistical methods were used to determine the effectiveness of the machining parameters on surface roughness. The influence of each milling parameter affecting surface roughness was analyzed using analysis of variance (ANOVA). The significant machining parameters affecting the surface roughness were the feed rate, spindle speed, and tool diameter (p < 0.05). There was no significant influence of axial depth of cut on the surface roughness. The surface roughness decreased with increasing spindle speed and decreasing feed rate. The value of surface roughness increased with the increase of tool diameter.

Study of Machining Parameter Optimization in Drilling of Magnesium Based Hybrid Composites Reinforced with SiC/CNT

2020 ◽  
Vol 846 ◽  
pp. 42-46 ◽  
Author(s):  
J.S.Suresh Babu ◽  
Min Heo ◽  
Chung Gil Kang
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Hybrid Composites ◽  
Spindle Speed ◽  
Influential Factor ◽  
Burr Formation ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Wide Range ◽  
Machining Parameter

Recently, researchers and engineers have been interested in the development of hybrid metal matrix composites (HMMCs) for the applications of automotive and aerospace industries owing to their superior properties due to the usage a wide range of material combinations in its manufacturing. The present study focuses on the machining of magnesium based hybrid composites reinforced with CNT (1vol.%) and SiC (2vol.%).The influence of machining parameters such as spindle speed, feed rate, drill diameter and point angle on burr formation and surface roughness on drilling the composites were investigated using Taguchi method. The drilling parameters were optimized by using ANOVA experimental design and also find out the percentage of contribution of each factor. Based on the results, the most influential factor for the burr thickness was spindle speed and point angle. While spindle speed and feed rate were the influencing factors for surface roughness. The analysis revealed that burr height, burr thickness, and surface roughness decreases significantly with an increase in spindle speed.

Drilling Of Tio2 and Zns Filled Gfrp Composites: A Taguchi Approach

2014 ◽  
Vol 4 (1) ◽  
pp. 42-54
Author(s):  
Arun K. V. ◽  
Sujay Kumar D. ◽  
Murugesh M. C.
Keyword(s):  
Thrust Force ◽  
Polymer Matrix Composites ◽  
Matrix Composites ◽  
Influence Of Process Parameters ◽  
Volume Fractions ◽  
The Matrix ◽  
Radial Drilling ◽  
Machine Speed ◽  
Tool Diameter ◽  
Drill Tool

The main affecting parameter for Delamination of the composites and in turn the failure of composites is the Thrust force. In the present work an attempt has been made in order to investigate the Thrust force generated during drilling of the TiO2 and ZnS filled Glass Fabric Reinforced Polymer Matrix Composites (GFRP). The volume fractions in the matrix were chosen as 1, 2 and3%. A plan of experiments, based on the techniques of Taguchi, was performed to acquire data in a controlled way. An L27 orthogonal array and analysis of variance (ANOVA) were employed to investigate the influence of process parameters on the drilling of these composites. Drilling has been conducted on a radial drilling machine. Speed of drilling (S), volume fractions (VF) and drill tool diameter (D) were considered as the varying parameters with three levels. Thrust force has been considered as the output parameter and is been measured in each combination of parameters chosen. Results reveal that, the addition of filler will increase the thrust force developed during drilling. As per ANOVA values, drill tool diameter contributes more towards generation of thrust, followed by speed of drilling. Main Effect plots shows that, contribution of speed towards thrust generation is only upto a certain level of increase in speed.

Study on Surface Roughness in Minimum Quantity Lubrication Turning of Al-6082/SiC Metal Matrix Composites

2019 ◽  
Vol 895 ◽  
pp. 127-133 ◽  
Author(s):  
C.J. Vishwas ◽  
M. Naik Gajanan ◽  
B. Sachin ◽  
Roy Abhinaba ◽  
N.P. Puneet ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composites ◽  
Feed Rate ◽  
Metal Matrix ◽  
Minimum Quantity Lubrication ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Matrix Composites ◽  
Minimum Quantity

Aluminum-based metal matrix composites (MMCs) have been suggested due to intense interest from automobile, marine, aerospace and other structural applications owing to their balanced mechanical, physical and chemical properties. MMCs are manufactured in order to meet present demand such as low material density, high mechanical strength and higher wear resistance of the component. Generally,MMCs tend to form rougher surface during machining because of the abrasive nature of hard ceramic particles present in them. Stir casting technique was used for fabrication of this composite which ensures better homogeneity.Furthermore, an attempt has been made in this paper to examine the results on the surface roughness of Al-6082/SiC metal matrix composites (containing 0%, 5% and 10% SiC particles).Focus was spent on parametric optimization of these composites in order to achieve cost-effective machining limits. The machining parameter studies have been carried out through the design of experiments (DoE) under minimum quantity lubrication (MQL) condition and effect of machining parameters such as spindle speed, feed rate and depth of cut on surface roughness was investigated to analyze the influence of reinforcement on surface roughness. In addition, analysis of variance was studied to obtain percentage contribution of machining parameters involved. Also, the surface morphology of the machined surface was studied through a scanning electron microscope (SEM). Distribution of SiC in aluminum alloy is fairly uniform with few clusters. Results of the experiments revealed that most significant turning parameter for surface roughness was spindle speed followed by feed rate and depth of cut. Furthermore, an optimal setting parameter for getting lower surface roughness was presented in confirmation table.

Drilling of Tio2 and Zns Filled Gfrp Composites

2017 ◽  
pp. 978-990
Author(s):  
Arun K. V. ◽  
Sujay Kumar D. ◽  
Murugesh M. C.
Keyword(s):  
Thrust Force ◽  
Polymer Matrix Composites ◽  
Matrix Composites ◽  
Volume Fractions ◽  
Thrust Generation ◽  
The Matrix ◽  
Radial Drilling ◽  
Machine Speed ◽  
Tool Diameter ◽  
Drill Tool

The main affecting parameter for Delamination of the composites and in turn the failure of composites is the Thrust force. In the present work an attempt has been made in order to investigate the Thrust force generated during drilling of the TiO2 and ZnS filled Glass Fabric Reinforced Polymer Matrix Composites (GFRP). The volume fractions in the matrix were chosen as 1, 2 and3%. A plan of experiments, based on the techniques of Taguchi, was performed to acquire data in a controlled way. An L27 orthogonal array and analysis of variance (ANOVA) were employed to investigate the influence of process parameters on the drilling of these composites. Drilling has been conducted on a radial drilling machine. Speed of drilling (S), volume fractions (VF) and drill tool diameter (D) were considered as the varying parameters with three levels. Thrust force has been considered as the output parameter and is been measured in each combination of parameters chosen. Results reveal that, the addition of filler will increase the thrust force developed during drilling. As per ANOVA values, drill tool diameter contributes more towards generation of thrust, followed by speed of drilling. Main Effect plots shows that, contribution of speed towards thrust generation is only upto a certain level of increase in speed.

scholarly journals Optimization of Surface Roughness in Deep Hole Drilling using Moth-Flame Optimization

2019 ◽  
Vol 18 (3-2) ◽  
pp. 62-68
Author(s):  
Anis Farhan Kamaruzaman ◽  
Azlan Mohd Zain ◽  
Razana Alwee ◽  
Noordin Md Yusof ◽  
Farhad Najarian
Keyword(s):  
Surface Roughness ◽  
Optimization Algorithm ◽  
Feed Rate ◽  
Spindle Speed ◽  
Hole Drilling ◽  
P Value ◽  
Machining Parameters ◽  
Deep Hole ◽  
Deep Hole Drilling ◽  
Moth Flame Optimization Algorithm

This study emphasizes on optimizing the value of machining parameters that will affect the value of surface roughness for the deep hole drilling process using moth-flame optimization algorithm. All experiments run on the basis of the design of experiment (DoE) which is two level factorial with four center point. Machining parameters involved are spindle speed, feed rate, depth of hole and minimum quantity lubricants (MQL) to obtain the minimum value for surface roughness. Results experiments are needed to go through the next process which is modeling to get objective function which will be inserted into the moth-flame optimization algorithm. The optimization results show that the moth-flame algorithm produced a minimum surface roughness value of 2.41µ compared to the experimental data. The value of machining parameters that lead to minimum value of surface roughness are 900 rpm of spindle speed, 50 mm/min of feed rate, 65 mm of depth of hole and 40 l/hr of MQL. The ANOVA has analysed that spindle speed, feed rate and MQL are significant parameters for surface roughness value with P-value <0.0001, 0.0219 and 0.0008 while depth of hole has P-value of 0.3522 which indicates that the parameter is not significant for surface roughness value. The analysis also shown that the machining parameter that has largest contribution to the surface roughness value is spindle speed with 65.54% while the smallest contribution is from depth of hole with 0.8%. As the conclusion, the application of artificial intelligence is very helpful in the industry for gaining good quality of products.

scholarly journals Effect of Cutting Parameter on Material Removal Rate and Surface Roughness in Deep Drilling Process

2016 ◽  
Vol 2 (5) ◽  
Author(s):  
Mostafa A. Abdullah  , Ahmed B. Abdulwahhab   ,   Atheer R.
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spindle Speed ◽  
Cutting Conditions ◽  
Drilling Process ◽  
Tool Diameter ◽  
Twist Drills

In the curents study aimed to assess the effects of cutting conditions  (spindle speed, feed rate, tool diameter) parameters as input impact on material removal rate (MRR) and surface roughness (Ra) as output of steel (AISI 1015). A number of drilling experiments were conducted using the L9 orthogonal array on conventional drilling machine with use feed rate (0.038,0.076,0.203) mm/rev and spindle speed (132,550,930) rpm and tool diameter (11,15,20) mm HSS twist drills under dry cutting conditions. Analysis of variance (ANOVA) was employed to determine the most significant control factors affecting on surface roughness and MRR. The result shown the tool diameter the important factor effect with (64.08%) and (76.12%) on MRR and surface roughness respectively.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

scholarly journals Surface roughness of thermally treated wood cut with different parameters in CNC router machine

BioResources ◽  
2021 ◽  
Vol 16 (3) ◽  
pp. 5133-5147
Author(s):  
Hüseyin Pelit ◽  
Mustafa Korkmaz ◽  
Mehmet Budakçı
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Treatment Temperature ◽  
Spindle Speed ◽  
Numerical Control ◽  
Machining Parameters ◽  
End Mill ◽  
Cnc Machine ◽  
Cnc Router ◽  
Thermally Treated

The effects of different machining parameters on surface roughness values of thermally treated pine, beech, and linden woods cut in a computer numerical control (CNC) router machine were examined. Wood specimens were thermally treated at 170, 190, and 210 °C for 2 h. Then, specimens were cut in the radial and tangential directions with three different spindle speeds (12000, 15000, and 18000 rpm) and three different feed rates (3000, 4000, and 6000 mm/min) using two different end mill tools (spiral and straight) on the CNC machine. The end mill type significantly affected the roughness values of the untreated and thermally treated specimens in both directions. Lower roughness values were found in the specimens (especially pine) machined with the straight end mill compared to those machined with the spiral end mill. Roughness generally decreased in the thermally treated specimens. However, thermal treatment temperature did not have a notable effect on roughness. As the spindle speed increased, the roughness values of all specimens decreased. In contrast, as the feed rate increased, the roughness values increased. Therefore, the end mill type, feed rate, and spindle speed were the most influential parameters on the roughness.

Modeling of Radial Over Cut in Electrochemical Machining of Al-B4C MMC Using Response Surface Methodology

2013 ◽  
Vol 13 (1-2) ◽  
pp. 31-36
Author(s):  
Sadineni Rama Rao ◽  
G. Padmanabhan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Electrochemical Machining ◽  
Machining Parameters ◽  
Matrix Composites ◽  
The Matrix ◽  
Contour Plots

AbstractElectrochemical machining (ECM) is increasing its importance in machining of metal matrix composites (MMC) due to some specific advantages which can be exploited during machining operation. In ECM the quality of the surface produced is also depends on the workpiece physical and electrical properties along with the process parameters like voltage, feed rate, electrolyte concentration, type of electrolyte, current, gap between electrodes etc. Therefore, in the present work the percentage of reinforcement of the particulates in the matrix is considered one of the process parameters along with the applied voltage, electrode feed rate and electrolyte concentration. A mathematical prediction model of the radial over cut (ROC) was developed using response surface methodology (RSM). The effects of electrochemical machining parameters on the Radial over cut were evaluated. The contour plots were drawn to study the effect of various process parameters and their interaction. In this work the predicted values and measured values are quite close to each other. Therefore, the developed model can be effectively used to predict the radial over cut on electrochemical machining of Al-B4C composites.

Sign in / Sign up

Export Citation Format

Share Document