Effect of drilling parameters on hole quality in drilling of pultruded GFRP composite material: Surface roughness, thrust force and delamination factor

Yıl 2023, Cilt: 12 Sayı: 4, 1573 - 1580, 15.10.2023

Kaan Emre Engin , Harun Yaka

https://doi.org/10.28948/ngumuh.1335448

Cited By: 2

Öz

The use of fiber reinforced composite materials (FRP) has increased in many areas. These materials need to be processed with some machining methods according to their usage areas, but their machinability is difficult. In this study, surface roughness (SR), delamination factor (Fd) and thrust forces were investigated in the drilling of glass fiber reinforced composite material (GFRP) produced by pultrusion with a coated and uncoated drill. Microstructures of chips formed during drilling were investigated and their effects on surface roughness were determined. Three different cutting speeds (60, 70, 80 m/min) and feed rates (0.06, 0.09, 0.12 mm/min) were selected as machining parameters. At the end of the study, it was found that feed rate had a more significant effect on surface roughness, delamination factor and thrust force. It was observed that as the cutting speed increased, the surface roughness, thrust force and delamination factor decreased. The lowest thrust force and Fd occurred at a cutting speed of 80 m/min and a feed rate of 0.06 mm/min. However, the lowest SR was obtained at a cutting speed of 70 m/min and a feed rate of 0.06 mm/min.Better results were obtained with TiN coated drills compared to uncoated drills.

Anahtar Kelimeler

GFRP, Drilling, Delamination factor, Thrust force, Surface roughness

Pultrüzyon ile üretilen GFRP kompozit malzemenin delinmesinde delme parametrelerinin delik kalitesine etkisi: Yüzey pürüzlülüğü, itme kuvveti ve delaminasyon faktörü

Öz

Fiber takviyeli kompozit malzemelerin birçok alanda kullanımı artmıştır. Bu malzemeler kullanım alanlarına göre bazı talaşlı imalat yöntemleri ile işlenmesi gerekmektedir fakat işlenebilirlikleri zordur. Bu çalışmada pultrüzyon ile üretilmiş cam fiber takviyeli kompozit malzemenin kaplamalı ve kaplamasız matkap ile delinmesinde yüzey pürüzlülüğü, delaminasyon faktörü ve itme kuvvetleri incelenmiştir. Delme sırasında oluşan talaşların mikro yapıları incelenmiş ve yüzey pürüzlülüğüne etkileri belirlenmiştir. İşleme parametreleri olarak üç farklı kesme hızı (60,70, 80 m/dk) ve ilerme oranı (0.06, 0.09, 0.12 mm/dk) seçilmiştir. Çalışma sonunda, ilerleme oranı yüzey pürüzlülüğü, delaminasyon faktörü ve itme kuvveti üzerinde daha belirgin etki yaptığı bulunmuştur. Kesme hızı arttıkça yüzey pürüzlülüğü, itme kuvveti ve delaminasyon faktörünün azaldığı görülmüştür. İtme kuvveti ve delaminasyon faktörü en düşük 80 m/dk kesme hızı ve 0.06 mm/dk ilerleme oranında oluşmuştur. Ancak en düşük yüzey pürüzlülüğü 70 m/dk kesme hızı ve 0.06 mm/dk ilerleme oranında çıkmıştır. TiN kaplı matkaplarda kaplamasız matkaplara kıyasla daha iyi sonuçlar elde edilmiştir.

Anahtar Kelimeler

GFRP, Delme, Delaminasyon faktörü, İtme kuvveti, Yüzey pürüzlülüğü

Kaynakça

• T. Lukács, C. Pereszlai and N. Geier, Delamination measurement in glass fibre reinforced polymer (GFRP) composite based on image differencing. Composites Part B: Engineering, 248, 110381, 2023. https://doi.org/10.1016/j.compositesb.2022.110381
• B. V. Kavad, A. B. Pandey, M. V. Tadavi and H. C. Jakharia, A review paper on effects of drilling on glass fiber reinforced plastic. Procedia Technology, 14, 457-464, 2014. https://doi: 10.1016/j.protcy.2014.08.058
• M. Kashikar, S. M. Patil and S. Kalkar, Experimental Study of Influence of Drilling Parameters on Delamination in Drilling Aircraft CFRP Composites Using DOE (Taguchi Method). Optimization of Industrial Systems, 499-518, 2022. https://doi.org/10.1002/9781119755074.ch39
• G. Kumar, S. M. Rangappa, S. Siengchin and S. Zafar, A review of recent advancements in drilling of fiber-reinforced polymer composites. Composites Part C: Open Access, 100312, 2022. https://doi.org/10.1016/j.jcomc.2022.100312
• D. Geng, Y. Liu, Z. Shao, Z. Lu, J. Cai, X. Li... and D. Zhang, Delamination formation, evaluation and suppression during drilling of composite laminates: A review. Composite Structures, 216, 168-186, 2019. https://doi.org/10.1016/j.compstruct.2019.02.099
• A. Dhandapani, S. Krishnasamy, R. Nagarajan, A. D. A. Selvaraj, S. M. K. Thiagamani, C. Muthukumar... and S. O. Ismail, Investigation of wear behavior in self-lubricating ABS polymer composites reinforced with glass fiber/ABS and glass fiber/carbon fiber/ABS hybrid. Lubricants, 11(3), 131, 2023. https://doi.org/10.3390/lubricants11030131
• E. Kilickap, Y. H. Çelik and B. Yenigun, Experimental Evaluation of Parameters Affecting Delamination Factor, Tensile Strength, Thrust Force And Surface Roughness In Drilling Of Gfrp. Surface Review and Letters, 30 (04), 2350025, 2023. https://doi.org/10.1142/S0218625X23500257
• V. Chadha, S. Gupta, R. M. Singari, Optimization of Cutting Parameters on Delamination Using Taguchi Method during Drilling of GFRP Composites. Proceedings of the International MultiConference of Engineers and Computer Scientists, 2, Hong Kong, 2017.
• R. A. Kishore, R. Tiwari, A. Dvivedi and I. Singh, Taguchi analysis of the residual tensile strength after drilling in glass fiber reinforced epoxy composites. Materials and design, 30 (6), 2186-2190, 2009. https://doi.org/10.1016/j.matdes.2008.08.035
• N. S. Mohan, A. Ramachandra and S. M. Kulkarni, Influence of process parameters on cutting force and torque during drilling of glass–fiber polyester reinforced composites. Composite structures, 71 (3-4), 407-413, 2005. https://doi.org/10.1016/j.compstruct.2005.09.039
• K. Shunmugesh, K. T. Akhil, S. Aravind and M. Pramodkumar, Optimization of drilling characteristics using grey-fuzzy logic in glass fiber reinforced polymer (GFRP). Materials Today: Proceedings, 4 (8), 8938-8947, 2017. https://doi.org/10.1016/j.matpr.2017.07.245
• R. Bhat, N. Mohan, S. Sharma, D. Pai and S. Kulkarni, Multiple response optimisation of process parameters during drilling of GFRP composite with a solid carbide twist drill. Materials Today: Proceedings, 28, 2039-2046, 2020. https://doi.org/10.1016/j.matpr.2020.02.384
• U. A. Khashaba, M. S. Abd-Elwahed, M. A. Eltaher, I. Najjar, A. Melaibari and K. I. Ahmed, Thermo-mechanical and delamination properties in drilling gfrp composites by various drill angles. Polymers, 13 (11), 1884, 2021. https://doi.org/10.3390/polym13111884
• A. T. Erturk, F. Vatansever, E. Yarar, E. A. Guven and T. Sinmazcelik, Effects of cutting temperature and process optimization in drilling of GFRP composites. Journal of Composite Materials, 55 (2), 235-249, 2021. https://doi.org/10.1177/00219983209471
• J. C. Rubio, A. M. Abrao, P. E. Faria, A. E. Correia and J. P. Davim, Effects of high speed in the drilling of glass fibre reinforced plastic: evaluation of the delamination factor. International Journal of Machine Tools and Manufacture, 48 (6), 715-720, 2008. https://doi.org/10.1016/j.ijmachtools.2007.10.015
• K. Palanikumar, Experimental investigation and optimisation in drilling of GFRP composites. Measurement, 44 (10), 2138-2148, 2011. https://doi.org/10.1016/j.measurement.2011.07.023
• M. Ramesh and A. Gopinath, Measurement and analysis of thrust force in drilling sisal-glass fiber reinforced polymer composites. IOP Conf. Series: Materials Science and Engineering, 197, 012056, 2017. https://doi.org/10.1088/1757-899X/197/1/012056
• A. T. Marques, L. M. Durão, A. G. Magalhães, J. F. Silva and J. M. R. Tavares, Delamination analysis of carbon fibre reinforced laminates: Evaluation of a special step drill. Composites Science and Technology, 69 (14), 2376-2382, 2009. https://doi.org/10.1016/j.compscitech.2009.01.025
• B. O. P. Soepangkat, R. Norcahyo, M. K. Effendi and B. Pramujati, Multi-response optimization of carbon fiber reinforced polymer (CFRP) drilling using back propagation neural network-particle swarm optimization (BPNN-PSO). Engineering Science and Technology, an International Journal, 23 (3), 700-713, 2020. https://doi.org/10.1016/j.jestch.2019.10.002
• S. R. Lu, C. Wei, J. H. Yu, X. W. Yang and Y. M. Jiang, Preparation and characterization of epoxy nanocomposites by using PEO-grafted silica particles as modifier. Journal of materials science, 42 (16), 6708-6715, 2007.
• A. Lotfi, H. Li and D. V. Dao, Machinability analysis in drilling flax fiber-reinforced polylactic acid bio-composite laminates. International Journal of Materials and Metallurgical Engineering, 13(9), 443-447, 2019.
• S. Dutta and S. K. R. Narala, Optimizing turning parameters in the machining of AM alloy using Taguchi methodology. Measurement, 169, 108340, 2021.https://doi.org/10.1016/j.measurement.2020.108340
• J. Xu, C. Li, M. El Mansori, G. Liu and M. Chen, Study on the frictional heat at tool-work interface when drilling CFRP composites. Procedia Manufacturing, 26, 415-423, 2018. https://doi.org/10.1016/j.promfg.2018.07.049
• A. Lotfi, H. Li and D. V. Dao, Machinability analysis in drilling flax fiber-reinforced polylactic acid bio-composite laminates. International Journal of Materials and Metallurgical Engineering, 13 (9), 443-447. 2019.
• K. Palanikumar, Modeling and analysis for surface roughness in machining glass fibre reinforced plastics using response surface methodology. Materials and design, 28 (10), 2611-2618, 2007. https://doi.org/10.1016/j.matdes.2006.10.001
• H. Yaka, Measurement of Surface Quality and Optimization of Cutting Parameters in Slot Milling of Gfrp Composite Materials with Different Fiber Ratios Produced by Pultrusion Method. Surface Review and Letters, 28 (10), 2150095, 2021. https://doi.org/10.1142/S0218625X21500955