The Investigation of Hole Delamination in Drilling Kevlar Composite Panel Using HSS Drill Tool

2020 ◽  
Vol 402 ◽  
pp. 108-114
Author(s):  
Mohd Iqbal ◽  
Firmansyah ◽  
Muhammad Tadjuddin ◽  
Laxman B. Abhang
Keyword(s):  
Feed Rate ◽  
Cutting Temperature ◽  
Spindle Speed ◽  
Composite Panel ◽  
Cutting Condition ◽  
Drilling Process ◽  
Delamination Factor ◽  
Drilling Condition ◽  
Tool Diameter ◽  
Drill Tool

The drilling process has been mostly used in composite panel machining to be a final product. It becomes a critical process when the composite product requires a high hole precision for the purpose of assembly and quality standard. Machining Kevlar composite is a difficult task due its hardness, fiber layer bounding and fiber orientation. The cutting condition needs to be controlled carefully to minimize the vibration, cutting temperature and hole delamination. This paper discusses the investigation of hole delamination in drilling Kevlar composite panel. The twist drill type of High-Speed Steel (HSS) drilling tool with 12 mm diameter was used to drill a 4 mm thick Kevlar composite panel. Three levels of spindle speed (1000 rpm, 1400 rpm and 2000 rpm) and three levels of feed rate (130 mm/min, 160 mm/min and 180 mm/min) were selected as the configuration of cutting condition. The hole diameter was measured and was compared to the drill tool diameter. The result of the experiment shows that the cutting condition gave significant effect to the drill hole delamination factor. The highest delamination factor was 1.36 and achieved by drilling condition with spindle speed of 1000 rpm and feed rate of 160 mm/min. The lowest delamination factor was 1.161 and achieved by drilling condition with spindle speed of 2000 rpm and feed rate of 130 mm/min.

scholarly journals Optimization of drilling process parameters on delamination factor of Jute reinforced unsaturated polyester composite using Box-Behnken design of experiment

2020 ◽  
Vol 14 (1) ◽  
pp. 6295-6303
Author(s):  
Zaleha Mustafa ◽  
N. H. Idrus ◽  
A B. Mohd Hadzley ◽  
D. Sivakumar ◽  
M. Y. Norazlina ◽  
...  
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Unsaturated Polyester ◽  
Spindle Speed ◽  
Drilling Process ◽  
Delamination Factor ◽  
Drilling Parameters ◽  
Polyester Composite ◽  
Tool Diameter ◽  
Drill Tool

This paper presents an investigation on the influence of the drilling parameters such as feed rate, spindle speed and drill tool diameter onto the delamination factor of the jute reinforced unsaturated polyester composite. Natural fibre based composite are mostly used for commodity application and often subjected to drilling during applications and may generate delamination of drilled holes on the workpiece. The composite was fabricated using woven jute fibre via vacuum bagging method followed a high temperature curing using hot press. The fibre was kept at 40 vol. %. The main effect and the interaction between the specified factors of feed rate (20-100mm/min), spindle speed (500-1500 rpm) and drill tool diameter (4-8 mm) with delamination factor as corresponding respond was structured via the Response Surface Methodology (RSM) based on three-level Box-Behnken design of experiment and the ANOVA. The levels of importance of the process parameters on flexural properties are determined by using Analysis of Variance (ANOVA). The optimised drilling process parameters obtained as 24.38 mm/min of feed rate, 1146.14 rpm of spindle speed and 5.51 mm drill tool diameter achieved the most minimal delamination factor. The feed rate and spindle speed were perceived as the most influential drilling parameters on the delamination factor of the jute reinforced unsaturated polyester composite.

Defect evaluation of the honeycomb structures formed during the drilling process

2019 ◽  
Vol 29 (3) ◽  
pp. 454-466
Author(s):  
P Ghabezi ◽  
M Farahani ◽  
A Shahmirzaloo ◽  
H Ghorbani ◽  
NM Harrison
Keyword(s):  
Feed Rate ◽  
Cutting Speed ◽  
Drilling Process ◽  
Delamination Factor ◽  
Drilling Parameters ◽  
Principal Factors ◽  
Novel Method ◽  
Full Factorial Experimental Design ◽  
Tool Diameter ◽  
Full Factorial

In this paper, a comprehensive experimental investigation was carried out to precisely characterize the delamination and uncut fiber in the drilling process. A digital imaging procedure was developed in order to calculate the damage resulted from the drilling process. A novel method is proposed in this article based on image intensity to verify the obtained results. A full factorial experimental design was performed to evaluate the importance of the drilling parameters. Among other process parameters, feed rate, cutting speed, and tool diameter are the principal factors responsible for the delamination damage size during the drilling. The drilling process was assessed based on two proposed incurred damage factors, specifically the delamination factor and uncut fiber factor. Experimental results demonstrated that the feed rate was the paramount parameter for both delamination and uncut fiber factors. It was observed that both factors increased with an increase in the feed rate. Additionally, by increasing the tool diameter, the delamination and uncut fiber factors significantly increase. The effects of the cutting speed on damage factors were not linear. The minimum delamination factor and uncut fiber factor were obtained at the cutting speed of 1500 and 2500 r/min, respectively.

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.

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 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.

Investigation, sensitivity analysis, and multi-objective optimization of effective parameters on temperature and force in robotic drilling cortical bone

2017 ◽  
Vol 231 (11) ◽  
pp. 1012-1024 ◽  
Author(s):  
Vahid Tahmasbi ◽  
Majid Ghoreishi ◽  
Mojtaba Zolfaghari
Keyword(s):  
Sensitivity Analysis ◽  
Feed Rate ◽  
Process Temperature ◽  
Drilling Process ◽  
Drilling Speed ◽  
Multi Objective Optimization ◽  
Bone Drilling ◽  
Multi Objective ◽  
Tool Diameter ◽  
First Time

The bone drilling process is very prominent in orthopedic surgeries and in the repair of bone fractures. It is also very common in dentistry and bone sampling operations. Due to the complexity of bone and the sensitivity of the process, bone drilling is one of the most important and sensitive processes in biomedical engineering. Orthopedic surgeries can be improved using robotic systems and mechatronic tools. The most crucial problem during drilling is an unwanted increase in process temperature (higher than 47 °C), which causes thermal osteonecrosis or cell death and local burning of the bone tissue. Moreover, imposing higher forces to the bone may lead to breaking or cracking and consequently cause serious damage. In this study, a mathematical second-order linear regression model as a function of tool drilling speed, feed rate, tool diameter, and their effective interactions is introduced to predict temperature and force during the bone drilling process. This model can determine the maximum speed of surgery that remains within an acceptable temperature range. Moreover, for the first time, using designed experiments, the bone drilling process was modeled, and the drilling speed, feed rate, and tool diameter were optimized. Then, using response surface methodology and applying a multi-objective optimization, drilling force was minimized to sustain an acceptable temperature range without damaging the bone or the surrounding tissue. In addition, for the first time, Sobol statistical sensitivity analysis is used to ascertain the effect of process input parameters on process temperature and force. The results show that among all effective input parameters, tool rotational speed, feed rate, and tool diameter have the highest influence on process temperature and force, respectively. The behavior of each output parameters with variation in each input parameter is further investigated. Finally, a multi-objective optimization has been performed considering all the aforementioned parameters. This optimization yielded a set of data that can considerably improve orthopedic osteosynthesis outcomes.

Experiments of Drilling Titanium Alloy with Varying Operation Parameters

2017 ◽  
Vol 748 ◽  
pp. 254-258
Author(s):  
Chang Yi Liu ◽  
Bai Shou Zhang ◽  
Suman Shrestha
Keyword(s):  
Titanium Alloy ◽  
Feed Rate ◽  
Thrust Force ◽  
Maximum Amount ◽  
Spindle Speed ◽  
Drilling Process ◽  
Process Variables ◽  
Experimental Cutting ◽  
Operation Parameters ◽  
Titanium Alloy Ti6al4v

Drilling experiments of titanium alloy Ti6Al4V were conducted. Taking the speed and feed as the process variables, a set of experimental cutting forces are obtained and compared. From the experimental results it is concluded that within the experimental extent the thrust force and torque of drilling process rises with the feed rate. The lower spindle speed resulted in the greater amount of thrust. Feed rates have greater influence on the thrust force than the spindle speed. The combination of greater feed rate and lower spindle speed results in the maximum amount of thrust. However, combination of greater feed rate and spindle speed resulted in maximum amount of torque.

Effects of Twist Drill Point Angle on Thrust Force and Delamination Factor in Hybrid Fiber Composites Drilling

2014 ◽  
Vol 564 ◽  
pp. 501-506 ◽  
Author(s):  
Mohd Azuwan Maoinser ◽  
Faiz Ahmad ◽  
Safian Shariff ◽  
Tze Keong Woo
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Polymeric Composite ◽  
Drilling Process ◽  
Twist Drill ◽  
Fiber Reinforced ◽  
Hybrid Fiber ◽  
Frp Composites ◽  
Delamination Factor ◽  
Drill Point

Drill point angle of twist drill has a significant effect on thrust force and delamination factor on drilled holes in fiber reinforced polymer (FRP) composites. In this study, three drill point angle of twist drill; 85°, 118° and 135° were used to drill holes in hybrid fiber reinforced polymeric composite (HFRP). HFRP composites were fabricated using vacuum infusion molding (VIM) technique. The test samples were cured at 90°C for two hours. In drilling process various drill point angle and feed rate were employed to investigate the effect of both parameters on thrust force and delamination factor when drilling the HFRP composite. The results showed that small drill point angle and low feed rate can reduce the thrust force leading to the reduction of damage factor at the holes entrance and exit.

Characterizing the Effect of Cutting Condition, Tool Path, and Heat Treatment on Cutting Forces of Selective Laser Melting Spherical Component in Five-Axis Milling

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Amir Mahyar Khorasani ◽  
Ian Gibson ◽  
Moshe Goldberg ◽  
Guy Littlefair
Keyword(s):  
Heat Treatment ◽  
Production Process ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Tool Path ◽  
Annealing Temperature ◽  
Spindle Speed ◽  
Cutting Condition ◽  
Scallop Height

Additive manufacturing (AM), partly due to its compatibility with computer-aided design (CAD) and fabrication of intricate shapes, is an emerging production process. Postprocessing, such as machining, is particularly necessary for metal AM due to the lack of surface quality for as-built parts being a problem when using as a production process. In this paper, a predictive model for cutting forces has been developed by using artificial neural networks (ANNs). The effect of tool path and cutting condition, including cutting speed, feed rate, machining allowance, and scallop height, on the generated force during machining of spherical components such as prosthetic acetabular shell was investigated. Also, different annealing processes like stress relieving, mill annealing and β annealing have been carried out on the samples to better understand the effect of brittleness, strength, and hardness on machining. The results of this study showed that ANN can accurately apply to model cutting force when using ball nose cutters. Scallop height has the highest impact on cutting forces followed by spindle speed, finishing allowance, heat treatment/annealing temperature, tool path, and feed rate. The results illustrate that using linear tool path and increasing annealing temperature can result in lower cutting force. Higher cutting force was observed with greater scallop height and feed rate while for higher finishing allowance, cutting forces decreased. For spindle speed, the trend of cutting force was increasing up to a critical point and then decreasing due to thermal softening.

Analysis and optimization of the surface waviness in the single-point incremental sheet metal forming

2018 ◽  
Vol 233 (4) ◽  
pp. 919-925
Author(s):  
Mohammad H Shojaeefard ◽  
Abolfazl Khalkhali ◽  
Shahaboddin Shahbaz
Keyword(s):  
Analysis Of Variance ◽  
Feed Rate ◽  
Single Point ◽  
Spindle Speed ◽  
Optimum Level ◽  
Surface Waviness ◽  
Taguchi Design Of Experiments ◽  
Vertical Step ◽  
Measuring Machine ◽  
Tool Diameter

Presence of waviness in the incremental sheet forming has a detrimental effect on the surface quality of parts, especially on the appearance of those covered with paint. In this paper, the effects of tool diameter, feed rate, spindle speed, and vertical step have been studied on the surface waviness using an innovative method. The proposed method is based on the root mean square deviation of the height of the points located on the wavy surface. In this way, some points are selected on the formed wall and their coordinates are measured using a coordinate measuring machine. Taguchi design of experiments and the analysis of variance are used for studying and optimizing the effects of the four process parameters and their combinations to minimize the waviness of the formed wall. The results show that by reducing the vertical step and increasing the tool diameter, the waviness is decreased. It is also found that the feed rate and the spindle speed have little effect on the waviness. Additionally, from a confirmation test, the results illustrate that the Taguchi method and the analysis of variance provide an efficient and effective method for determination of the optimum level of each process parameter to have the minimum surface waviness.

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