Machinability of glass fiber reinforced plastic (GFRP) composite materials

Abstract

This paper deals with the study of machinability of GFRP composite tubes of different fiber orientation angle vary from 30 0 to 90 0. Machining studies were carried out on an all geared lathe using three different cutting tools: namely Carbide (K-20), Cubic Boron Nitride (CBN) and Poly-Crystalline Diamond (PCD). Experiments were conducted based on the established Taguchi's Design of Experiments (DOE) L 25 orthogonal array on an all geared lathe. The cutting parameters considered were cutting speed, feed, depth of cut, and work piece (fiber orientation). The performances of the cutting tools were evaluated by measuring surface roughness (Ra) and Cutting force (Fz). A second order mathematical model in terms of cutting parameters was developed using RSM. The results indicate that the developed model is suitable for prediction of surface roughness and Cutting force in machining of GFRP composites.

Investigation of optimum cutting parameters and tool radius in turning glass-fiber-reinforced composite material

“…They evaluated the cutting parameters based on delaminate factors, surface roughness, international dimensional precision, and cutting parameters in two different GFRP composite materials. They showed that feed rate was the most prominent parameter affecting cutting force and that surface roughness increased with feed rate and decreased with cutting speed, which was also confirmed by other authors [6,7,10,16] . Kalla et al [8] developed a methodology for estimating cutting forces in carbon-fiber-reinforced polymers by using helical end mill in various fiber orientations.…”

“…In this concept, contradictory results are available in the literature. While some colleagues are claiming that cutting speed significantly affects surface quality [13, 14, 16 -19, 21, 22] , some others are claiming that it does not affect significantly [6,7,15,20,22] . The inconsistency arises perhaps from the experimental environment and the tools used.…”

“…It analyzed plane deformation of incompressible reinforced composites structured with strong parallel fibers [5,6] . Since then, the research in this field has continuously developed and expanded in both synthesis and analysis perspectives.…”

“…Since GFRP composites are extremely abrasive, proper selection of the cutting tool and cutting parameters is needed for a perfect machining process [13] . In this direction, a variety of studies have been conducted on analyzing the effects of cutting parameters, insert radius, as well as derivatives of these parameters on the surface roughness of different composite materials with various cutting tools [6,13,14] , cutting speeds [6, 7, 10, 15 -19] , feed rates [6, 7, 10, 15 -17] , and fiber orientation [6,7] . Also, a variety of analyzing strategies such as optimizing cutting parameters using multiple analysis regression [16] , hand lay-up making use of orthogonal array, and analysis of variance statistical technique [16] have been developed.…”

Multiple performance characteristics optimisation in side and face milling of glass fibre reinforced polyester composite at different weightage of performances by grey relational analysis

“…After then predicated thrust force values and measured thrust force values through experiments had been compared with each other. Hussain et al (2011) developed a surface roughness and cutting force prediction model for machining GFRP tubes using RSM by using carbide tool (K 20 ), cubic boron nitride (CBN) and polycrystalline diamond tool. Four parameters namely cutting speed, feed, depth of cut and work piece (fibre orientation) were selected to minimise the surface roughness and cutting forces.…”