Analysis of drilling-induced geometrical damages in basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

Abstract

Basalt fibre-reinforced polymer (BFRP) composites probably tend to replace some carbon fibre-reinforced polymer (CFRP) applications due to their excellent specific strengths and sustainability. Despite the published early promising results concerning the material properties of BFRP, their application is not widespread, and their machinability is not supported widely by published experiences. The main aim of the present study is to experimentally investigate the drilling-induced geometrical damages of BFRP and CFRP composites. Drilling experiments were conducted at various feed and cutting speed levels using a solid carbide twist drill. The drilling-induced burr was analysed by a Mitutoyo 361–804 digital microscope, a Mitutoyo SJ400 surface tester recorded the surface roughness, and the microstructure was analysed by a Zeiss Evo MA 10 scanning electron microscope. The measured data were evaluated through digital image processing (DIP), response surface methodology (RSM), and analysis of variances (ANOVA). The experimental results show that drilling-induced burr is more severe and surface roughness is worse in BFRP than in CFRP. The composite type influenced the geometrical damages primarily, followed by the feed in the case of burrs and by the cutting speed in the case of surface roughness. The present experimental study suggests that the drilling of BFRP is even more challenging than drilling CFRP from the point of view of burr formation and micro geometrical properties.

Improved mechanical and fire-retardant properties of fiber-reinforced composites manufactured via modified resins and metallic thin films

“…In these studies, some process parameters (inclusion types, concentrations, curing temperature and time, thickness, etc.) were analyzed to determine better flame test parameters [28,29]. The prepared composite panels were cut into pieces for making test specimens by using a diamond saw cutter where water was used as a coolant, and finally, all edges were smoothed with a fine grinder (sandpaper) to remove microcracks, voids, scratches, and dents before further testing.…”

Analysis and modelling of thrust force in drilling of basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

“…Our industrial partner provided both composites, as they plan to replace their CFRP components with the more sustainable BFRP composite. The main material properties of the composites were measured and published in our previous study [23].…”

“…The composite type as a categorical factor with two levels (BFRP and CFRP) and the feed (mm/rev) and cutting speed (m/min) as continuous factors, each on three different levels, were varied according to the experimental table as is shown in Table 2. The levels of these continuous factors (Table 1) were defined based on previous studies and the recommendations of the tool manufacturers [7,23,30,31]. The experimental design is suitable for the application of quadratic models to describe nonlinear influences of process parameters.…”

“…Presumably, this is due to the fact that the smaller feed rate reduces the chip cross section, resulting in a lower cutting force, although a detailed scientific investigation has not been carried out in the past. Magyar et al [23] conducted drilling experiments in BFRP composites and analysed the influences of process parameters on the drilling-induced burr and microstructure. They showed that the cutting speed has the most significant influence on surface roughness, and the effect of the feed is negligible.…”

Regression model-based parametric analysis of drilling of multi-walled carbon nanotubes-added glass fiber composite laminates

“…The extensive research in this field, as evidenced by studies such as those conducted by Bayraktar and Turgut [21], Kastabha et al [22], Raja et al [23], Mohan Kumar et al [24], and others [25][26][27][28][29][30][31], highlights the critical importance of understanding the effects of various drilling parameters. These studies have collectively advanced the knowledge of how factors like feed rate, cutting speed, drill geometry, and material composition influence drilling outcomes such as delamination, thrust force, surface roughness, and hole quality.…”