distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Abstract
Drilling in composite materials causes versatile damages, such as: delamination,
fibre-pull out, edge chipping, uncut fibers and others. Delamination is said to be an empirical problem associated with drilling fiber reinforced composite materials. Thrust force has been cited as an imperative cause of delamination. The present work vertically tailors to establish a correlation between cutting parameters namely thrust force and delamination. Drilling experimental trials were carried out on basalt/sisal polymer composites material using HSS twist drill. The data obtained through drilling are processed by "Minitab 17" software package. The analysis of achieving the optimality condition are performed through 3286 M. Sakthivel et al.
ANOVA, regression model and response diagram (RD) to evaluate the best mathematical input models for making drilling in fabricated composite. The analysis reveals the optimized parameter to control thrust force and delamination factor in basalt/sisal fibre is Drill bit diameter at 3mm, speed at 300 rpm and feed rate at 0.1mm/rev.
1. Introduction The natural reinforcement of composites like primarily glass is scarcely found in commercial products namely boats, skis, agricultural machinery and cars. Imperative goal of natural fibre composites is to alleviate the need for use in expensive glass fibre ($3.25/kg), which has relatively high density (2.5 g/cm³) and is interdependent on non renewable sources. [1-2].Natural fibres are now considered as a serious alternative over glass fibres, to act as reinforcing agents in composite materials.[3].The composites are manufactured in near net shape processes, but they do require secondary machining operations for assembling in commercial applications. Thus leverages drilling, cutting and machining to be performed in composites for nurturing to get a final shape. The drilling is a typical operation (reaming is rarely employed for polymeric composites) that are prone mainly due to delamination with rejection rate of approximately 60% of drilled components produced in aircraft industry [4-5].Delaminating occurs due to cracking of composites laminate with the contact of the drill bit, the induced delamination occurs at both entrance and exit planes of work piece. Delamination occurs mainly due to increase in feed rate at the end of drilling that will cause cracking around the exit edge of the hole [6].Taguchi, elaborately bifurcates the signal to noise variations into three various quality characteristics namely Higher- the-better, Nominal-the-better and Lower-the-better [7]. The regression identifies the outlier, which is the difference between actual and the target value. The outliers in the experimental data are evaluated through standardized, R-student test [8].
2. Experimental Method 2.1 Material and fabrication The basalt and sisal fiber combination selected in this case was uncovered since basalt is equivalent to glass fiber. The sisal was procured from local resources and basalt from muktagiri agencies, Mumbai. Both fibers embedded in epoxy resin. Epoxy resin obtained from local resources. Hybrid laminates prepared by simple hand layup process in a mold at room temperature. The combination was used for this study i.e. Basalt (20%) Sisal (20%) embedded in epoxy resin. Drilling analysis on basalt/sisal reinforced polymer composites 3287
3. Results and Discussion
The current work concentrates on the evaluation of machinability properties, by performing drilling operation on (BSRPC). The radial drilling machine was used for drilling hole on BSRPC. The drill tool dynamometer was used for measuring thrust force and coral draw software used for measuring the delamination. The prolong investigation reveals the machinable process parameters as drill bit diameter, speed and feed rate,each varying at three levels namely Level – 1,Level-2 and Level-3 with lower setting,actual setting and higher setting. The selected factors and levels urges to construct OA with nine treatment points as illustrated below
The table 1 reveals the experimental results of multi responses namely thrust and delamination factor with their signal to noise (S/N) ratio of Lower the better (LB) quality characteristics. The results obtained are analyzed by generating the Analysis of variance (ANOVA) and regression equation for individual responses. The below table illustrate ANOVA for thrust force as given.
Table 2. Analysis of Variance for Mean (Thrust)
Source DF Seq SS Adj SS Adj MS F P %contribution
Drill bit 2 53.633 53.6331 26.8165 140.25 0.007 40.38% diameter Speed 2 18.267 18.2674 9.1337 47.77 0.021 13.97% Feed rate 2 60.536 60.5360 30.2680 158.30 0.006 45.77% Error 2 0.382 0.3824 0.1912 Total 8 132.819 3288 M. Sakthivel et al.
The ANOVA for thrust force in table 2 reveals that feed rate highly influence the thrust force at 45.77% followed by drill diameter at 40.38% and speed at 13.97%.The speed influentiality on the thrust force occurs due to size in hole made and opposing force of fibres in composites. The linearity from the obtained data is monitored through linear regression residual plot and Response Diagram (RD) as given below.
Fig 1. Regression plot and RD for S/N for thrust force
The summary of the regression model reveals, that the outliers in the model for thrust force response is within the acceptable range with the determination coefficient (R2) stands at 99.80% for the input factors speed, drill bit diameter and feed rate for drilling with BSRPC.The RD in figure-1 reveals the best levels to control the thrust force from unnecessary variations are by selecting drill bit diameter at 3mm, speed at 300rpm and feed rate at 0.1 mm/rev.
Table 3. Analysis of Variance for means (Delamination)
Similarly the ANOVA was made up for delamination in table 3 reveals, that feed rate highly influence the delamination which stood at 91.84% followed by influentiality of drill bit diameter at 2.4% and speed at 4.25% in drilling of BSRPC material. The speed influentiality on delamination occurs due to feed force increases which causes higher friction and produces more damage on the surface. The residual plot, RD regression equation, as given below. Drilling analysis on basalt/sisal reinforced polymer composites 3289
Fig 2. Regression plot and RD for S/N for delamination
A summary of the regression model,RD reveals that outliers in the model for delamination response is with determination coefficient (R2) stands at 98.6% with best level of input factors at drill bit diameter of 5mm,speed at 300rpm and feed rate with 0.1 mm/rev for drilling in BSRPC.
4. Conclusion The conclusions drawn from this work are as follows: The optimum process parameters are chosen for drilling in BSRPC with Drill bit diameter at 3mm, speed at 300 rpm and feed rate at 0.1mm/rev for monitoring thrust force and delamination whose results obtained provides impetus concomitant.
References [1] Mohantya, A. K., Misraa, M., Hinrichsen, G., Biofibres, Biodegradable Polymers and Biocomposites: An Overview, Macromolecules and Material Engineering, 2000, 276/277, 1-24. http://dx.doi.org/10.1002/(sici)1439-2054(20000301)276:1<1::aid-mame1>3.0.co;2-w
[9] Latha B, V.S Senthil Kumar, “fuzzy rule based modeling of drilling parameters for delamination in drilling GRPF composites, journal of Reinforced plastics and composite, 28 (2008), 951-964. http://dx.doi.org/10.1177/0731684407087570
Received: December 15, 2014; Published: April 20, 2015
