Machining and Machinability of Fiber Reinforced Polymer Composites (original) (raw)
Related papers
2017
Delamination is one of the most common defects occur during drilling of carbon fiber reinforced polymer composites. It is an inter-ply failure phenomenon and it has to be minimized to have better quality of drilled holes for structural applications. The current study is conducted to investigate the effect of machining parameters (spindle speed, drill diameter, feed rate and point angle) on delamination while drilling of 60-40 weight % and 55-45 weight % of bi-directional carbon fiber reinforced polymer (BD CFRP) composites with titanium nitride (TiN) coated solid carbide drills. Taguchi L27 orthogonal array is used for determining the experimental results of delamination and the Taguchi methodology is also employed for determining the predicted results of delamination of both BD CFRP composite laminates. The investigation reveals that there is a good concurrence between the experimental and the predicted results of delamination. The main effect plot shows that the drill diameter has...
This paper describes the experimental investigation in the drilling of glass fiber reinforced polymer (GFRP) composites with three dissimilar tools, having different materials and geometries (i.e. helical flute (HSS) drill, Carbide tipped straight shank (K20) drill, and Solid carbide eight-facet drill). Tool geometry and materials are considered to be major factor, which is responsible for drilling-induced damage. Cutting parameters also influence drillinginduced damage. These damages were measured by two delamination factors. Image processed technique was utilized to determine the damaged area and maximum damaged zone diameter. The results showed that qualities of drill holes significantly improved when solid carbide eight-facet drill was used.
Glass fiber reinforced plastic (GFRP) composite materials are widely used industrial, aerospace, and automotive sector. Its have excellent properties such as high strength to weight ratio, higher fatigue limit high stiffness to weight ratio, corrosion resistance and design flexibility. Drilling is one of the major machining operations that are carried out on fiber reinforced metal composite materials to the need for components assembly. There are many problems encountered when drilling Glass fiber reinforced plastic (GFRP) composites. These problems include delaminating of the composite, poor surface roughness and hole deviation. In present experimental investigation analyse the effect of various machining parameters i.e. cutting speed, the feed rate, and the drill diameter on the quality of the drilled holes. Hole deviation of each hole is measured with help of digital vernier calliper. Taguhi's and ANOVA Technique have been employed to study the effect of the interactions between different drilling parameters on deviation of holes. After experiments suggests the optimal conditions for minimum hole deviation.
Drilling of GFRP Composites for Minimising Delamination Effect
Materials Today: Proceedings, 2017
Drilling of glass fibre reinforced composites is difficult due to high structural stiffness and low thermal conductivity of plastics. Laminate composites consisting of layers of plies are prone to delamination during drilling operation. Selection of appropriate drilling process parameters is very essential to reduce the damage in glass fibre reinforced composites. The effect of cutting parameters like speed and feed rate during drilling process for both experiment and numerical simulation has been studied and analysed in this work. Experimental and numerical simulation quantification of delamination effect induced by drilling is performed using Image J. The experimental results agree reasonably with numerical simulation.
Analysis of Delamination Factor in Drilling of CFRP Composites Using Design of Experiments
The use of Carbon Fibre Reinforced Polymer (CFRP) composites has increased rapidly in recent times. Due to the complex cutting mechanism irregularities occur in the surface. The delamination factor should be minimized to obtain better surface quality. In this study, a CFRP composite material were drilled to experimentally minimize the delamination factor on the machined surfaces, using a drilling machine with different combinations of cutting parameters namely point angle, spindle speed, feed rate. Experimental results showed that the delamination factor increased rapidly with increasing spindle speed and lesser increase of delamination factor for feed rate and a very small change for point angle. In addition, analysis of variance (ANOVA) results clearly shows that the spindle speed was the most influential parameter affecting the delamination factor in drilling of CFRP composites. Response Surface Methodology (RSM) technique was adopted to optimize the responses and the relation between factors and response was plotted in 2D and 3D contour plots. 1. Introduction CFRP composites are already made to near net shape and machining is carried out for deburring, trimming and to achieve contour shape accuracy [1]. In CFRP metal removal is conducted at lower rates because small cutting depths produce smaller and fewer cracks. Most of the metals are replaced by Carbon Fibre Reinforced Plastics (CFRP) composite because they are economic and have high strength. They have a wide variety of applications in automotive, aircraft, construction, spaceship, interior design, sports goods and sea vehicles industries due to their light weight, high modulus, specific strength, high resistance to corrosion and high fracture toughness [2]. The machining of composite is different from the conventional machining of metal due to the composite's anisotropic and non-homogeneous nature [3].CFRP composite materials are extremely abrasive when machined. Thus the selection of the cutting tool and the cutting parameters is very important in the machining process [4]. During the process of machining of CFRP laminates due to the action of machining force the composites tend to delaminate and in order to improve the dimensional accuracy, performance and production, the cutting conditions that influence delamination factor should be optimized. For achieving the desired machining force, it is necessary to understand the mechanisms of the material removal, and the kinetics of machining processes affecting the performance of the cutting tool [5]. The machinability of the composites is mainly dependent on the cutting parameters namely spindle speed, feed and depth of cut. Paulo Davim and Mata (2007) proposed a new machinability index for turning FRP materials using polycrystalline diamond (PCD) and cemented carbide (K15) cutting tools. According to the study it was found that PCD tools had better surface finish and specific cutting pressure than cemented carbides [6]. Paulo Davim et al [7] established that the cutting parameters (feed and dept of cut) influence the machining force, delamination, dimensional precision and surface roughness in two composites (Viapal VUP 9731 and ATLAC 382-05). The orthogonal Design of Experiments of Taguchi has been applied to investigate the effect of the fiber orientation, the tool rake angle, the depth of cut, and the tool edge radius. The induced damage can strongly affect the surface roughness (surface quality of the work pieces) and considerably limits the use of these materials in many industrial applications. Satisfactory numerical results have been found and a good correlation has been obtained compared to experimental trends. The results reveal that the interaction between some factors could be neglected and the obtained responses are greatly influenced by the fiber orientation and the depth of cut rather than the tool rake angle and the tool edge radius [8]. Machining of composite materials, have shown that the surface quality (surface roughness), and delamination factor is strongly dependent on cutting parameters, tool geometry and cutting forces. [9-13]. In this study, the experiments were carried out using RSM technique the machining force was observed for second order response surface and the validity of the experiment was checked using analysis of variance (ANOVA). The machining parameters namely point angle, spindle speed and feed rate were selected in order to analyze the delamination factor. Response Surface Methodology (RSM) is a sequential process which involves a series of mathematical and statistical techniques which is used to analyze the problems and produce the optimizing the responses. By experimentation and regression analysis the independent variables of a response model are found and in turn used to find out the optimal point of the response. The relationship between control factors and response can also be found and respective 2-D and 3-D plots could be generated.
Drilling of Glass Fibre Reinforced (GFRP) Epoxy Composite Materials- an Experimental Study
— Fiber reinforced polymer composites have gained substantial attention as engineering structural materials in automotive, marine and aircraft industry as well as in civil engineering applications. This is due to their outstanding mechanical properties, impact resistance, high durability and flexibility in design capabilities and light weight. However, the delamination and the unstable crack growths are inherent problems associated with these fabric reinforced composites. Damage of composite structures through delamination are unstable crack growth perhaps the most important aspects of mechanical behavior which limit the wide applications of these materials. Machining of composite materials is difficult to carry out due to the anisotropic and non-homogeneous structure of composites and to the high abrasiveness of their reinforcing constituents. This typically results in damage being introduced into the work piece and very rapid wear development in the cutting tool. Conventional machining processes such as turning, drilling or milling can be adapted to composite materials, provided proper tool design and operating conditions are maintained. The present work also describes the machining (drilling) of GFRP composites with the help of Step drill of three sets, with three different speeds. Further work has been carried out by immersion of GFRP composites in sea water for 8 hrs, 16 hrs and 24 hrs duration and performed drilling operation. Results revealed that 8-4 mm step drill showed better machining characteristic than the other two 12-8 mm and 10-6 mm step drills. The ZnS Filled GFRP composites had better performance than TiO2 filled GFRP Composites.
2021
The aim of this work is to define the cutting conditions that allow the drilling of added glass fiber reinforced epoxy composite materials by taking into consideration the exit delamination factor, thrust force and the optimum combination of drilling parameters. The experiments were carried out under two cutting parameters such as cutting speed and feed rate for three levels each. Taguchi experimental design is used to reduce the excessive number of experiments. The experiment design was accomplished by application of the statistical analysis of variance (ANOVA). Correlations between cutting speed/feed rate and the various machining parameters were established to optimize cutting conditions. These correlations were found by quadratic regression using response surface methodology (RSM). Multiple regression analysis (MRA) was also employed to establish parametric relationships between the experimental parameters and the machinability outputs consisting of delamination and thrust force...
Polymers, 2020
Carbon fibre-reinforced polymer (CFRP) composite materials play an increasingly important role in modern manufacturing, and they are among the more prominent materials used in aircraft manufacturing today. However, CFRP is highly prone to delamination and other damage when drilled due to it being extremely strong with a good strength-to-weight ratio and high thermal conductivity. Because of this problem and CFRP’s growing importance in aircraft manufacture, research has focused on the entry and exit holes as indicators of damage occurrence during drilling of screws, rivets, and other types of holes. The inside of the hole was neglected in past research and a proper way to quantify the internal side of a hole by combining the entry and exit hole should be included. To fill this gap and improve the use of CFRP, this paper reports a novel technique to measure the holes by using the extension of the adjusted delamination factor (SFDSR) for drilling thick CFRP composites in order to esta...
Drilling of uni-directional glass fiber reinforced plastic (UD-GFRP) composite laminates
The International Journal of Advanced Manufacturing Technology, 2006
Drilling of fiber reinforced plastic (FRP) composite materials is a field open to a plethora of questions. Drillinginduced damage is a research area that has not been explored exhaustively. The present research endeavor is an effort to correlate drilling-induced damage with drilling parameters. Tool point geometry is considered a major factor that influences drillinginduced damage. Experiments were conducted and drillinginduced damage was quantified using the digital image processing technique. The results also reestablished the cutting speed to feed ratio as an important variable that influences drillinginduced damage. Mathematical models for thrust, torque, and damage are proposed that agree well with the experiments.
Drilling of Glass Fibre Reinforced Plastic
Advanced Materials Research, 2012
Nowadays composite materials are used in many industrial areas. The main application of these is the aircraft industry. Problematic points with machining of composite materials are tool wear, tool life, delamination and temperature during machining of polymer composite materials. Paper focuses on investigation of delamination at drilling of glass fibre reinforced composites. Experiments were planned on the base so called design of experiment - DOE. We observed the evolution of delamination at investigations, when we combined 4 different variables (vc, fz, tool, cooling system). We investigated the evolution of force relations, torques, dimensional and shape accuracy, considering on delamination. We processed results statistically, for processing we used software MINITAB and MATLAB. We summarized results in tables and graphs.