Drilling On Glass Fiber Reinforced Composite Material For .
International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comDrilling on Glass Fiber Reinforced Composite Material forEnhancement of Drilling Quality: A ReviewGautam Shankar TatePost graduation StudentDepartment of Production Engineering,Karmaveer Bhaurao Patil College ofEngineering, Satara.E-mail:- gautam tate@rediffmail.comAamir M. ShaikhAssistant ProfessorDepartment of Production Engineering,Karmaveer Bhaurao Patil College ofEngineering, Satara.E-mail:- amir.shaikh@kbpcoes.edu.inAnant Dattatray AwasareAssistant ProfessorDepartment of Mechanical Engineering,DACOE, Karad (M.S.), India.E-mail:- anant280@gmail.comAbstract:GFRC mostly used in the industries due to theirhigh mechanical properties such as high strengthto-weight and stiffness-to-weight ratios. Ourobjective is to reduce delimitation of GFRC workpiece by selecting process parameters and toolparameters. By selecting suitable ranges of theparameters as per the convenience and by selectingthe drilling machine as per availability we made thedrilled holes. Inspecting the drilled holes on toolmakers' microscope, analysis of delimitation factorfor each drilled hole was done. By comparing thedelimitation factor of various drill holes we foundthe suitable range of parameter in which thedelimitation was least. By improving the quality ofdrill we can improve the life of the work piece.Classification of composite according to matrix thecomposite may classify as follows:A composite material can be distinct as a mixtureof a matrix and a reinforcement, which whencombined gives properties higher to the propertiesof the individual components. In the case of acomposite, the reinforcement is the fibres and isused to fortify the matrix in terms of strength andstiffness. The reinforcement fibres can be cutaligned placed in different ways to affect theproperties of the resulting composite. The matrix,normally a form of resin, keeps the reinforcementin the desired orientation. It protects thereinforcement from chemical and environmentalattack, and it bonds the reinforcement so thatapplied loads can be effectively transferred.Keywords: Reinforcement, Environmental attack,stiffness-to-weight1. Metal Matrix Composites (MMCs)I. Introduction2. Polymer Matrix Composites (PMCs)Engineering materials are changing faster and thechoice is wider than ever before. This is mainlybecause of the expansion in materials, processes,and computational abilities. Advanced high – techindustries adopted new materials and processes;replacement of mild steel with high strength steel,lighter non – ferrous alloys, such as aluminium andmagnesium alloys, plastics, and composites. Manyindustries developing high strength, low weightmaterials for wide applications such as compositematerials. The machining of composite materials isa growing problem in various fields such asaeronautical, automotive, wind turbine industries.In particular, the drilling of these materials,required to assemble different parts, is difficult tocontrol and often leads to delaminating at the exitof the laminates. This can affect the strength of thestructure. This project involves experimental andanalytical investigation of drilling on Glass fibrereinforced plastic material [2].3. Ceramic Matrix Composites (CMCs)4. Intermetallic Matrix Composites (IMCs)5. Carbon Carbon Composites (CCCs)The technological and commercial interest incomposite material lies in their superior propertiesof strength-to-weight, stiffness-to-weight, fatigueand thermal expansion compared to metals.Extensive use of composite in application such asrockets, satellites, missiles, light combat aircraft,advanced light helicopter and trainer air craft hasshown that India is on par with the advancedcountries in the development and use of compositesin this area.The machining of composite materials is a growingproblem in various fields such as aeronautical,automotive, wind turbine industries [3].923
International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.com. It reduces the compressive strength ofcomposite material It reduce considerable amount oftoughness. It can be formed due to tensile stresses atthe notches Failure of material due to delaminationcan cause human harm.II. Literature ReviewP. Rahme et.al [1] had been studied analyticalmodel was developed to determine the criticalthrust force at delamination at the hole exit. Thismodel gives the drilling thrust force as a functionof the cutting conditions. Finally, the twoconsidered models are used to determine theoptimal cutting conditions for delamination-freedrilling. The results are validated numerically andexperimentally. A drilling thrust force model isdeveloped in order to calculate the drilling forces ofeach zone in function of the feed rate per tooth. Theresults of the two proposed models are used tocalculate the critical feed rate per tooth, atdelamination, in the case of a large-diameter twistdrill, without thinning its chisel edge. These feedrates are determined for the two zones of the drill.They are calculated according to the number of thenon-drilled plies remaining under the drill. Themost critical feed rate per tooth corresponds to thelowest value.Fig1: Composite materialDELAMINATION:Delamination is a critical failure mechanism , and is one of the key factorsdifferentiating their behavior from that of metallicstructures. It is caused by high inter laminarstresses in conjunction with the typically very lowthrough-thickness strength. The phenomenon arisesbecause fibers lying in the plane of a laminate donot provide reinforcement through the thickness,and so the composite relies on the relatively weakmatrix to carry loads in that direction. This iscompounded by the fact that matrix resins aretypically quite brittle. Delamination failure may bedetected in the material by its sound as shown infig.2.Tom Sunny et.al [2] had been studied the effect ofspeed and feed on delamination behavior ofcomposite materials by conducting drillingexperiments using Taguchi’s L25, 5-levelorthogonal array and Analysis of variance by usingthree different tools namely Twist drill, End milland Kevlar drill. ANOVA was used to analyse thedata obtained from the experiments and finallydetermine the optimal drilling parameters indrilling Glass fibre reinforced composite (GFRP)materials. Results of these experiments revealedthat increasing the spindle speed and reducing feedrate can reduce the delamination within limits ofspecified speed and feed rates. Too low feed rateand too high spindle speed can also increase thedelamination. Results also revealed that feed rate isthe more influential factor on delamination thanspindle speed.Patil A.A [3] had done review on drilling oncomposite material, It has been predicted that mostof the problem associated with hole makingFig2. Delamination924
International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comcomposites were observed, both at the entrance andthe exit during the drilling. Moreover, this paperpresents the application of Taguchi method andanalysis of variance (ANOVA) for minimization ofdelamination influenced by drilling parameters anddrill point angle. The optimum drilling parametercombination was obtained by using the analysis ofsignal-to-noise ratio. The conclusion revealed thatfeed rate and cutting speed were the mostinfluential factor on the delamination, respectively.The best results of the delamination were obtainedat lower Student cutting speeds and feed rates.operation, such as drilling, can be attributed to theforce generated during cutting operation. Manydevelopments and experiments are going ondrilling of Sandwich composite for damage freedrilling along with the quality of the hole and theeffect of tool geometry and tool material. Thispaper aims at the comprehensive analytical andexperimental investigation work done on thecomposites material.R.A. Kishore et al.[4] Studied the effect of thecutting speed, the feed rate, and the drill pointgeometry on the residual tensile strength of thedrilled unidirectional glass fiber reinforced epoxycomposite using the Taguchi method and suggeststhe optimal conditions for maximum residualtensile strength. Three important parameters, that isthe drill point geometry, the cutting speed and thefeed rate have been studied. The optimum levels ofthe drill point geometry, the cutting speed and thefeed rate have been established for gettingmaximum residual tensile strength in drilled UDGFRP laminates. The maximum residual strength isfound with 8-facet drill at cutting speed of 750 rpmand feed rate of 15 mm/min. It is observed that thedrilling-induced damage at higher cutting speedsseverely affects the residual tensile strength ofdrilled laminates. The optimum selection of thedrill point geometry is also important to ascertainthe minimum drilling induced damage andsubsequently the maximum residual tensilestrength.S. Arul et al. [7] Drilling trials have been carriedout on glass Fibre reinforced plastics (GFRP) withplain high speed steel (HSS), TiN coated HSS andtipped tungsten carbide drills. Most of the defectsin drilling of composites are due to thrust forceexperienced by the work piece. The parametricinfluence on cutting force was experimentallyevaluated. The experimental results show that thedefects toleranced drilling can be attained byproper selection of cutting parameters and toolmaterial. This is substantiated by monitoring flankwear, hole shrinkage and acoustic emission duringdrilling.Birhan Isık [8] had given new comprehensiveapproach to select cutting parameters for damagefactor in drilling of glass fiber-reinforced polymer(GFRP) composite material. The influence ofdrilling on surface quality of woven GFRP lly. Drilling tests were carried outusing carbide drills of 8 mm in diameter at 50, 70,and 90 m/min cutting speeds and at 0.06, 0.12, and0.18 mm/rev feed rates. Damage factor wasinvestigated based on hole entrance and exit.Analysis of variance (ANOVA) test was applied tothe experimental results. The compared valueswere employed by Duncan test to identify whichgroups were significantly different from othergroups.C. C. Tsao [5] Analyzed the Taguchi method fordrilling quality associates with core drill. The thrustforce and surface roughness of core drill with drillparameters (grit size of diamond, thickness, feedrate and spindle speed) in drilling Carbon FiberReinforcement Plastic (CFRP) laminates wasexperimentally investigated. Composite materialfor drilling was fabricated using autoclave molding.A L27 orthogonal array and signal-to-noise(S/N) were employed to analyze the effect ofdrill parameters. Using Taguchi method for designof a robust experiment the interaction amongfactors is also investigated. For thrust force,thickness and feed rate are the most significantfactors and for surface roughness, the feed rate andspindle speed are the most significant factors indrilling GFRP laminates as experimentally andanalytically obtained. In general high speed andlow drilling feed rate are recommended for theproduction of delamination free and good surfacefinish holes in epoxy composites.J. Campos Rubio et al.[9] done work on employsHSM to realize high performance drilling of glassfibre reinforced plastics (GFRP) with reduceddamage. In order to establish the damage level,digital analysis is used to assess delamination. Acomparison between the conventional (Fd) andadjusted (Fda) delamination factor is presented.The experimental results indicate that the use ofHSM is suitable for drilling GFRP ensuring lowdamage levels.B.V.Kavad et.al. [10] had done review oninfluence of machining parameter on thedelamination damage of GFRP during drilling. Inconventional machining feed rate, tool material andcutting speed are the most influential factor on thedelamination hence machining at higher speed,E. Kilickap [6] Investigate the influence of thecutting parameters, such as cutting speed and feedrate, and point angle on delamination producedwhen drilling a GFRP composite. The damagegenerated associated with drilling GFRP925
International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comharder tool material and lower feed rate have lesserdelamination of the GFRP. Vibration assisteddrilling and Ultrasonic assisted drilling have lesserthrust and hence lesser delamination compared toconventional drilling, which indicates that bothvibration assisted drilling and Ultrasonic assisteddrilling are more appropriate for drilling of GFRP.IV. MethodologyThe methodology of presents investigation includefollowing steps:Step1: Selection of raw material and preparation ofGFRC plate of required dimension.III. Problem IdentificationStep2: Selection of machine.The machining of composite materials is a growingproblem in various fields such as aeronautical,automotive, wind turbine industries. The drilling ofthese materials, required to assemble differentparts, is difficult to control and often leads todelamination at the exit of the laminates. This canaffect the strength of the structure. Analysis andstudy of this machining process can be helpful forreducing induction of stresses and preventingchange in dimension of component. Drilling isimportant and mostly used machining process.Analysis and study of Drilling process can behelpful for reducing induction of stresses.Step3: Selection of drill.Process Parameters:Step9: Analysis of results.1.2.3.Step4: Selection of drilling parameter.Step5: Selection of levels and parameter values.Step6: Selection of Taguchi method to optimiseparameters.Step7: Conduction of experiment.Step8: Recommending optimum level of machiningparameters while concluding work.Step10: Result and discussion with conclusion.Cutting speedFeed rateDepth of cutConclusionI have concluded in this Paper work is to evaluateand optimize the effect of process parameters viz.speed, feed rate, and depth of cut for response ofsurface roughness and material removal rate anddelamination factor. The effect of machiningparameters will be identified for optimum outcome.Taguchi analysis method will be selected for designof experiment.Performance Measures:1.2.3.Delamination factorMaterial removal rateSurface roughnessIV. ObjectivesReferences1. To improve the quality of drill with minimumdelamination.[1] P. Rahme, Y. Landon , F. Lachaud , R. Piquet ,P. Lagarrigue, “Delamination-freedrilling ofthick composite materials”, Science Direct,Composites: Part A 72 (2015) 148–159.2. To study delamination factor using variousparameters[2] Tom sunny, J.Babu, Jose Philip,ExperimentalStudies on “Effect of Process Parameters onDelamination in Drilling GFRP Composites usingTaguchi Method”, Procedia Materials Science 6 (2014 ) 1131 – 1142.3. To study the effect of cutting speed, feed rate &depth of cut on surface roughness, material removalrate (MRR) and delamination factor of thecomposite material.4. To study the effect of variation of machiningparameter on response factor.[3] Patil A.A., Shende M.D. “Experimental andAnalytical Investigation of Drilling of SandwichComposites”: A Review. IOSR Journal ofMechanical and Civil Engineering, 2013, vol. 6,iss. 6,pp. 40–52. DOI: 10.9790/1684-0664052.5. To study the contribution of parameters onresponse factor.[4] R.A. Kishore, R. Tiwari, A. Dvivedi, I. Singh ,“Taguchi analysis of the residual tensile strength926
International Journal of Engineering Research and Technology. ISSN 0974-3154 Volume 10, Number 1 (2017) International Research Publication House http://www.irphouse.comafter drilling in glass fiber reinforced epoxycomposites”, Materials and Design 30 (2009)2186–2190.[5] C. C. Tsao, “Taguchi analysis of drilling qualityassociated with core drill in drilling of compositematerial”; International Journal of AdvancedManufacturing Technology, vol. 32, 2007, pp 877884.[6] E. Kilickap, “Optimization of cuttingparameters on delamination based on Taguchimethod during drilling of GFRP composite”,Exdert Systems with Applications 37 (2010) 6116–6122.[7] S. Arul, L. Vijayaraghavan, S. K. Malhotra, R.Krishnamurthy, “Influence of tool material ondynamics of drilling of GFRP composites”, DOI10.1007/s00170-005-2581-5, Int J Adv ManufTechnol (2006) 29: 655–662.[8] Birhan Işık, Ergün Ekici, “Experimentalinvestigations of damage analysis in drilling ofwoven glass fiber-reinforced plastic composites”,Int J Adv Manuf Technol (2010) 49:861–869 DOI10.1007/s00170-009-2440-x.[9] J. Campos Rubio, A.M. Abrao, P.E. Faria, A.Esteves Correia, J. Paulo Davim, “Effects of highspeed in the drilling of glass fibre reinforcedplastic: Evaluation of the delamination Factor”,International Journal of Machine Tools &Manufacture.[10] B. V. Kavad, A.B.Pandey, M.V.Tadavi,H.C.Jakharia , A Review Paper on, “Effects ofDrilling on Glass Fiber Reinforced Plastic”,Procedia Technology 14 (2014 ) 457 – 464.927
piece by selecting process parameters and tool parameters. By selecting suitable ranges of the parameters as per the convenience and by selecting the drilling machine as per availability we made the drilled holes. Inspecting the drilled holes on tool makers' microscope, analys
Glass Fiber Reinforced Polymer (GFRP) is a fiber reinforced polymer made of a plastic matrix reinforced by fine fibers of glass. Fiber glass is a lightweight, strong, and robust material used in different industries due to their excellent properties. Although strength properties are somewhat lower than carbon fiber and it is less stiff,
Recommended Practice for Glass Fiber Reinforced Concrete Panels - Fourth Edition, 2001. Manual for Quality Control for Plants and Production of Glass Fiber Reinforced Concrete Products, 1991. ACI 549.2R-04 Thin Reinforced Cementitious Products. Report by ACI Committee 549 ACI 549.XR. Glass Fiber Reinforced Concrete premix. Report by ACI .
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