Drilling Polymeric Matrix Composites

Capello, E.; Langella, A.; Nele, Luigi; Paoletti, A.; Santo, Loredana; Tagliaferri, V.

doi:10.1007/978-1-84800-213-5_6

Cited by 11 publications

(4 citation statements)

References 48 publications

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“…In many areas where composite materials are applied, mechanical bonding methods are preferred to stick bonding methods. The reason for this is that it is difficult to disassemble the bonding methods and the damage they have caused to the part during removal (Capello et al, 2008). It is not realistic to add the holes to the part during the molding phase, mainly due to the natural shrinkage occurring at this stage and the complexity of the equipment in the molding (Bradley, 2010).…”

Section: Introductionmentioning

confidence: 99%

Surface quality optimization of CFRP plates drilled with standard and step drill bits using TAGUCHI, TOPSIS and AHP method

Sur

Erkan

2020

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Purpose Drilling of carbon fiber reinforced plastic (CFRP) composite plates with high surface quality are of great importance for assembly operations. The article aims to optimize the drill geometry and cutting parameters to improve the surface quality of CFRP composite material. In this study, CFRP plates were drilled with uncoated carbide drill bits with standard and step geometry. Thus, the effects of standard and step drill bits on surface quality have been examined comparatively. In addition, optimum output parameters were determined by Taguchi, ANOVA and multiple decision-making methods. Design/methodology/approach Drill bit point angles were selected as 90°, 110° and 130°. In cutting parameters, three different cutting speeds (25, 50 and 75 m/min) and three different feeds (0.1, 0.15 and 0.2 mm/rev) were determined. L18 orthogonal sequence was used with Taguchi experimental design. Three important output parameters affecting the surface quality are determined as thrust force, surface roughness and delamination factor. For each output parameter, the effects of drill geometry and cutting parameters were evaluated. Input parameters affecting output parameters were analyzed using the ANOVA method. Output parameters were estimated by creating regression equations. Weights were determined using the analytic hierarchy process (AHP) method, and multiple output parameters were optimized using technique for order preference by Similarity to An ideal solution (TOPSIS). Findings It has been determined from the experimental results that step drills generate smaller thrust forces than standard drills. However, it has been determined that it creates greater surface roughness and delamination factor. From the Taguchi analysis, the optimum input parameters for Fz step tool geometry, 90° point angle, 75 m/min cutting speed and 0.1 mm/rev feed. For Fd, are standard tool geometry, 90° point angle, 25 m/min cutting speed and 0.1 mm/rev feed and for Ra, are standard tool geometry, 130° point angle, 25 m/min cutting speed and 0.1 mm/rev feed. ANOVA analysis determined that the most important parameter on Fd is the tip angle, with 56.33%. The most important parameter on Ra and Fz was found to be 40.53% and 77.06% tool geometry, respectively. As a result of the optimization with multiple criteria decision-making methods, the test order that gave the best surface quality was found as 4–1-9–5-8–17-2–13-6–16-18–15-11–10-3–12-14. The results of the test number 4, which gives the best surface quality, namely, the thrust force is 91.86 N, the surface roughness is 0.75 µm and the delamination factor is 1.043. As a result of experiment number 14, which gave the worst surface quality, the thrust force was 149.88 N, the surface roughness was 3.03 µm and the delamination factor was 1.163. Practical implications Surface quality is an essential parameter in the drilling of CFRP plates. Cutting tool geometry comes first among the parameters affecting this. Therefore, different cutting tool geometries are preferred. A comparison of these cutting tools is discussed in detail. On the other hand, thrust force, delamination factor and surface roughness, which are the output parameters that determine the surface quality, have been optimized using the TOPSIS and AHP method. In this way, this situation, which seems complicated, is presented in a plain and understandable form. Originality/value In the experiments, cutting tools with different geometries are included. Comparatively, its effects on surface quality were examined. The hole damage mechanism affecting the surface quality is discussed in detail. The results were optimized by evaluating Taguchi, ANOVA, TOPSIS and AHP methods together.

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Section: Introductionmentioning

confidence: 99%

Surface quality optimization of CFRP plates drilled with standard and step drill bits using TAGUCHI, TOPSIS and AHP method

Sur

Erkan

2020

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“…The hole damage involves delamination, fiber pull-out, fiber-matrix debonding, cracks, thermal damage and matrix cratering. The incidence and growth of the different damages depend on characteristics of tool material and PMCs, tool geometry and the drilling parameters [2]. The most important damage is delamination which may arise on the workpiece entry and exit.…”

Section: Introductionmentioning

confidence: 99%

Investigations on Drilling of Bidirectional Cotton Polyester Composite

Chaudhary

Gohil

2015

Materials and Manufacturing Processes

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Cotton fiber composites are currently used in the interior parts of automobiles, insulation boards, fiber boards and various parts of high-friction mechanical assemblies. These composites are subjected to machining operations. Drilling is an indispensable machining operation for assembly of different parts. The present work aimed to experimental and analytical investigations on drilling of bi-directional cotton polyester composite.Influence of feed, spindle speed and drill point angle on machining characteristics like thrust force, torque and delamination factor was studied by conducting experiments derived from Taguchi's L27 orthogonal array. To determine the significance of each drilling process parameters and their interactions analysis of variance (ANOVA) test was conducted. Modeling of drilling parameters was carried out through multiple regression analysis and their optimization for minimizing cutting forces and machining induced damage was carried out using S/N ratio analysis.

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“…[10][11][12][13] The effect of temperature dependent laminate matrix property consideration for critical thrust force predictions during delamination onset for varying temperatures was shown in. 14 CFRPs are considered hard to machine materials, 1,15,16 its inherent low transverse thermal conductivity leads to undesirable heat accumulation during dry machining resulting in significant reduction in load carrying ability. [17][18][19][20] A linear evolution of delamination damage over tool life was observed during CFRP drilling using uncoated drills.…”

Section: Introductionmentioning

confidence: 99%

In-situ cutting temperature and machining force measurements during conventional drilling of carbon fiber polymer composite laminates

Kubher

Gururaja

Zitoune

2021

Journal of Composite Materials

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The evolution of in-situ cutting temperature and machining forces during conventional drilling of multi-directional carbon fiber reinforced polymer (MD-CFRP) laminates using a novel inverted drilling setup is presented. The in-situ cutting temperature was measured using fiber Bragg grating (FBG) optical sensor embedded in the stationary drill. The effect of machining parameters such as spindle speed and feed rate on the temperatures and machining forces were studied that indicate the predominant effect of spindle speed on machining temperatures. The drilled MD-CFRP samples and drill bits were characterized by scanning electron microscopy (SEM) and micro-computed tomography ([Formula: see text]) techniques to assess machining-induced damage in the samples and tool wear in the drill bits. Exit-ply delamination was observed in MD-CFRP samples that aggravates with increase in cutting temperature and thrust force caused by evolving tool wear. The measured in-situ machining temperatures using the current experimental setup can be used to achieve better machining models.

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Drilling Polymeric Matrix Composites

Cited by 11 publications

References 48 publications

Surface quality optimization of CFRP plates drilled with standard and step drill bits using TAGUCHI, TOPSIS and AHP method

Surface quality optimization of CFRP plates drilled with standard and step drill bits using TAGUCHI, TOPSIS and AHP method

Investigations on Drilling of Bidirectional Cotton Polyester Composite

In-situ cutting temperature and machining force measurements during conventional drilling of carbon fiber polymer composite laminates

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