Experimental Investigation of Thrust Force, Delamination and Surface Roughness in Drilling Hybrid Structural Composites

Vigneshwaran, S.; Uthayakumar, M.; Rajendran, S.; Veerasimman, Arumugaprabu; Basha, Adamkhan Mahaboob; Majid, M.S. Abdul; Neisiany, Rasoul Esmaeely; Sas, Gabriel; Razavi, Seyed Mohammad Javad; Das, Oisik

doi:10.3390/ma14164468

Cited by 12 publications

(7 citation statements)

References 24 publications

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“…Various common methods are employed to mitigate this problem. These include the manufacture of drills with varied shapes and quality levels, adjusting cutting parameters for optimization, and implementing peck drilling techniques [ 19 , 20 , 21 , 22 , 23 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites

et al. 2023

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Carbon fiber-reinforced plastics (CFRPs) have been specially developed to enhance the performance of commercial and military aircraft because of their strength, high stiffness-to-density ratios, and superior physical properties. On the other hand, fasteners and joints of CFRP materials may be weak due to occurring surface roughness and delamination problems during drilling operations. This study’s aim is to investigate the drilling characterization of CFRPs with different drilling parameters and cutting tools. Drilling tests were performed with the Taguchi orthogonal array design (L18: 2^1 3^3). Tests were conducted with three levels of cutting speed (15, 30, 45 m/min), three levels of feed rate (0.05, 0.1, 0.2 mm/rev), two levels of drill diameter (3 and 5 mm), and three different types of drills (two twist drills with a point angle of 138° and 120° and one brad drill). Thrust forces were recorded during drilling tests, and afterwards surface roughness and hole delamination were measured. Obtained results were analyzed with Taguchi and two-way ANOVA. The general tendency was that low cutting speed, high feed rate, and small diameter drill caused an increase in thrust force. Surface roughness decreases with increasing tool diameter, decreasing feed, and cutting speed. Delamination factors of the samples dropped depending on decreasing thrust force levels. Remarkably, it is possible to control the delamination factor values via better surface quality. The brad drill and larger point angle have a negative effect on the drilling quality of CFRPs. According to all results, the cutting speed of 45 m/min and feed rate of 0.05 mm/rev using a type II drill having a 120° point angle and 5 mm diameter (12th trial) and the cutting speed of 30 m/min and feed rate of 0.05 mm/rev using a type II drill having a 120° point angle and 3 mm diameter (2nd trial) were determined as optimum drilling conditions.

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Section: Introductionmentioning

confidence: 99%

Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites

et al. 2023

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“…This laminated Al–PE composite also undergoes a drilling process for mounting applications. Numerous studies in the literature discuss the mechanical and machining characterization of such materials [ 11 , 12 , 13 ]. For instance, Gao et al [ 14 ] reported that, when the bonding strength of the steel/Al/steel composite interface is low, delamination first occurs on the exterior of the bending, as seen in their study on the effect of bond strength on the formability of steel/aluminum composite panels.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

et al. 2023

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Aluminum Matrix Composite (AMC) represents an innovative class of materials that is extensively utilized in industries such as automotive, defense, aerospace, structural engineering, sports, and electronics. This study investigates the thrust force, exit burr formation, changes in the micro-tool, and drilled hole diameters during the micro-drilling of an aluminum-polyethylene composite panel (Al–PE). The panel consists of 3501 series aluminum skin materials bonded to a polyethylene (PE) core. Micro-drilling test parameters were designed using Taguchi’s L16 (42 23) orthogonal array. Tests were conducted with five control parameters: cutting speed with four levels (10 m/min, 20 m/min, 30 m/min, 40 m/min), feed rate with four levels (0.5 µm/rev, 1 µm/rev, 2 µm/rev, 4 µm/rev), the tool diameter with two levels (0.7 mm, 1 mm), and tool point angle with two levels (100°, 140°) using both AlTiN-coated and uncoated drills. The maximum thrust force (Fz), maximum burr height, and changes in both the drill tool and hole diameters were measured for analysis of variance (ANOVA). The results showed that, in terms of impact on Fz, tool point angle had the highest positive influence (64.54%) on the micro-drill at the entrance of composite (upper aluminum plate). The cutting speed had the highest positive influence (45.32%) on the tool in the core layer (PE core layer). The tool point angle also had the highest positive influence (68.95%) on the micro-drill at the lower layer of the composite (the lower aluminum plate). There was noticeable chip adhesion on the major cutting edge and nose area under micro-drilling conditions with higher thrust forces and burr height. The AlTiN coating had a positive effect on tool wear and hole diameter deviations, but it adversely affected the burr height.

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“…These composites attract more attention in modern applications, especially in many engineering structures and constructions because of their light weight and increased strength compared to conventional materials. 5 Aluminum Alloys are soft and high strength materials. 7075 aluminum alloy used as a matrix material in this study is one of the most widely used non-ferrous materials in engineering applications due to its attractive properties such as high strength to weight ratio, good ductility, excellent corrosion, availability, and low cost.…”

Section: Introductionmentioning

confidence: 99%

Effect of TiB₂ and GNP reinforcements on machinability in drilling of Al7075/TiB₂/GNP hybrid composites produced by powder metallurgy

Yağmur,

Pul

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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In this study, it has been aimed to investigate the machinability performances by drilling by producing Al7075 matrix hybrid composite samples with graphenenanoplate (GNP) and titaniumdiboride (TiB2) reinforced at different rates by powder metallurgy. The impacts of GNP and TiB2 reinforcing materials on the cutting parameters and wear behavior of the cutting tool have been examined and discussed. As a result of the drilling tests which are carried out by applying different cutting parameters, it was observed that GNP additive has positive impact on the cutting forces, surface roughness, and hole quality in general. As a result of the machining experiments, the lowest cutting force was obtained as 150 N at a feed rate of 0.100 mm/rev and a cutting speed of 60 m/min in the 1% GNP reinforced sample. The minimum roughness value was obtained as 0.886 micron at 60 m/min cutting speed in the 1% GNP reinforced sample. The minimum deviations from cylindricality and circularity were also measured as 0.03 and 8.005 mm from the 1% GNP reinforced sample. While the lubricating effect was low with a GNP ratio of 0.5%, the abrasive effect was observed more with a GNP ratio of 1.5%. While GNP supplementation decreased the diameter deviation and cylindrical deviation values, it increased the perpendicularity deviation values. In general, swarf chip formation occurred with a small amount of flank wear on the cutting tools. While hard TiB2 reinforcement particles in the composite structure were effective in flank wear, the most important cause of chip formation was the presence of ductile aluminum matrix and relatively low cutting speeds. When the entire experimental study was evaluated, it was evaluated that the solid lubricant property of the GNP reinforcement material was effective at the most 1% GNP reinforcement rate.

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Experimental Investigation of Thrust Force, Delamination and Surface Roughness in Drilling Hybrid Structural Composites

Cited by 12 publications

References 24 publications

Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites

Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

Effect of TiB₂ and GNP reinforcements on machinability in drilling of Al7075/TiB₂/GNP hybrid composites produced by powder metallurgy

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Experimental Investigation of Thrust Force, Delamination and Surface Roughness in Drilling Hybrid Structural Composites

Cited by 12 publications

References 24 publications

Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites

Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

Effect of TiB2 and GNP reinforcements on machinability in drilling of Al7075/TiB2/GNP hybrid composites produced by powder metallurgy

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Effect of TiB₂ and GNP reinforcements on machinability in drilling of Al7075/TiB₂/GNP hybrid composites produced by powder metallurgy