Surface Roughness Analysis of Carbon/Glass Hybrid Polymer Composites in Drilling Process Based on Taguchi and Response Surface Methodology

Abstract

Drilling is an essential secondary process for near net-shape of hybrid composite as to achieve the required dimensional tolerances prior to final application. Dimensional tolerance is often influenced by the surface integrity or surface roughness of the workpart. Thus, this paper aims to employ the Taguchi and response surface methodologies in minimizing the surface roughness of drilled carbon-glass hybrid fibre reinforced polymer (CGCG) using tungsten carbide, K20 drill bits. The effects of spindle speed, feed rate and tool geometry on surface roughness were evaluated and optimum cutting conditions for minimizing the aforementioned response was determined. Subsequently, response surface methodology (RSM) was utilised in finding the empirical relationships between experimental parameters and surface roughness based on the Taguchi results. The experimental analyses reveal that surface roughness is greatly influenced by feed rate and tool geometry rather than the spindle speed. This is due to the increment of feed that attributed to the increased strain rate and hence, deteriorated the surface roughness of the hybrid composite. The predicted results (via regression model) and theoretical results (via additivity law) were in good agreement with experiment results. This indicates that the regression model from response surface methodology (RSM) can be used to predict the surface roughness in machining of CGCG hybrid composite.

Optimization and sensitivity analysis of drilling parameters for sustainable machining of carbon fiber–reinforced polypropylene composites

“…(ii) The increase in drill speed may also result in cutting of fibers owing to the absences of drill tool bouncing and softening of matrix martial which may results in lower order of responses. (iii) The wide range of thrust force (40-85 N) and torque (15)(16)(17)(18)(19)(20)(21)(22)(23)(24)(25)(26)(27)(28) was observed with HSS drill material for the tested limits of spindle speed (500-2500 r/min) and feed rate (0.05-0.25 mm/r). But SC drill material showed marginal variations initially due to its high hardness, high stiffness, and keenness of cutting edge.…”

“…Basavarajappa et al 26 have developed the RSM model for quantifying the process responses with essential input parameters. Tan et al 27 have formulated the regression model using RSM to forecast process responses in drilling of CF/GF hybrid composite material and they have concluded that the quality of drilled holes is highly affected by drill geometry and feed rate. Rajmohan and Palanikumar 28 have developed a model and optimized the drilling process parameters through RSM-based D-optimal design.…”

Fabricating Different Laminate Composites by Manual Layup and Estimating the Optimum Parameters for CNC Milling Machine

“…9, the last layer have been a fiber layer, that means two layers were separated from the base square. As seen in table (6) and 7, SN ratios and ANOVA tables, showed results of the significant factors, F-value and P-value and contribution of each parameter. Feed rate is the most significant factor by 70%, while spindle speed affects the lowest by 6%.…”

“…Tan et al [6] the author in his research used woven carbon fibers, woven E-glass fibers, in EpoxAmite matrix and hardener resin as the materials. The direction of woven carbon (C) and glass (G) fibers were organized in the grouping of [CGCG] these fibers were stacked in the glass mold until thickness 4 mm has been accomplished and they were fixed and compacted with vacuum sack under a vacuum from 11 to 15mBar.…”

“…[388][389][390][391][392][393][394][395][396] 2020 Alkhafaji et al 50:1 then the specimen is left in open air for 7 days for full solidification of the resin. The four specimens are shown in figure(6).…”