Currently, the use of sustainable products and technologies is growing; consequently, mineral-origin basalt fibre-reinforced polymer (BFRP) composites are becoming more popular in industries. Although BFRP parts require mechanical drilling operations for manufacturing holes for assembly, many challenges make the drilling process difficult. Considering that the cutting force is one of the main parameters characterising the drilling process, this study aims to analyse the influence of feed (mm/rev) and cutting speed (m/min) on the thrust force and model the thrust force in the drilling of BFRP composites through response surface methodology (RSM) and advanced statistical modelling methods. In order to determine main and interaction effects and to calculate the regression coefficients and model parameters, mechanical drilling experiments were performed, and the thrust force was recorded. The raw force data were processed using fast Fourier transformation-based low-pass filtering, and then the calculated thrust force parameters were evaluated relative to various feeds and cutting speeds. In addition, results were compared with those of carbon fibre-reinforced polymer composites. The results of the validation experiments show that both RSM and advanced statistical models accurately predict the thrust force in BFRPs of 96.74% and 95.01%, respectively. However, the advanced statistical model can describe not only the maximum values of the force but also its characteristics at a coefficient of determination of 0.68.
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.
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