Analysis of Milling Process Parameters and their Influence on Glass Fiber Reinforced Polymer Composites (RESEARCH NOTE)

Authors

1 Department of Mechanical Engineering, St Mary’s integrated campus, JNTU, Hyderabad, India

2 Department of Mechanical Engineering, T.K.R.CET, JNTU, Hyderabad, India

3 Department of Mechanical Engineering, J.N.T.U Hyderabad, India

Abstract

Milling of fiber reinforced polymer composites is of great importance for integrated composites with other mating parts. Improper selection of cutting process parameters, excessive cutting forces and other machining conditions would result in rejection of components. Therefore, machining conditions are optimized to reduce the machining forces and damages. This work reports practical experiments in milling, to study the effect of machining conditions on cutting force, surface roughness and damage factor of Glass Fiber Reinforced Polymer (GFRP) composites. The experiments were carried out with a designed carbide end mill tool by a random set of milling process parameters. The results showed that machined surface integrity was highly influenced by the spindle speed followed by the feed rate. The results of the experiments were illustrated and analyzed by interaction plots and Scanning Electron Microscope (SEM) images.

Keywords


1.     Jahanmir, S., Ramulu, M. and Koshy, P., "Machining of ceramics and composites, Marcel Dekker,  (1999).
2.     Ramulu, M., Wern, C. and Garbini, J., "Effect of fibre direction
 
on surface roughness measurements of machined graphite/epoxy composite", Composites Manufacturing,  Vol. 4, No. 1, (1993), 39-51.
3.     Jenarthanan, M. and Jeyapaul, R., "Evaluation of machinability index on milling of GFRP composites with different fibre orientations using solid carbide endmill with modified helix angles", International Journal of Engineering, Science and Technology,  Vol. 6, No. 4, (2014), 1-10.
4.     Sreenivasulu, R., "Optimization of surface roughness and delamination damage of GFRP composite material in end milling using taguchi design method and artificial neural network", Procedia Engineering,  Vol. 64, (2013), 785-794.
5.     Kumar, S. and Satsangi, P., "Multiple-response optimization of turning machining by the taguchi method and the utility concept using uni-directional glass fiber-reinforced plastic composite and carbide (k10) cutting tool", Journal of Mechanical Science and Technology,  Vol. 27, No. 9, (2013), 2829-2837.
6.     Gopalakannan, S. and Senthilvelan, T., "Optimization of machining parameters for EDM operations based on central composite design and desirability approach", Journal of Mechanical Science and Technology,  Vol. 28, No. 3, (2014), 1045-1052.
7.     Rao, G.V.G., Mahajan, P. and Bhatnagar, N., "Machining of ud-GFRP composites chip formation mechanism", Composites Science and Technology,  Vol. 67, No. 11, (2007), 2271-2281.
8.     Arola, D., Ramulu, M. and Wang, D., "Chip formation in orthogonal trimming of graphite/epoxy composite", Composites Part A: Applied Science and Manufacturing,  Vol. 27, No. 2, (1996), 121-133.
9.     Bhattacharyya, D. and Horrigan, D., "A study of hole drilling in kevlar composites", Composites Science and Technology,  Vol. 58, No. 2, (1998), 267-283.
10.   Bhattacharyya, D., Allen, M. and Mander, S., "Cryogenic machining of kevlar composites", Material and Manufacturing Process,  Vol. 8, No. 6, (1993), 631-651.
11.   Enemuoh, E.U., El-Gizawy, A.S. and Okafor, A.C., "An approach for development of damage-free drilling of carbon fiber reinforced thermosets", International Journal of Machine Tools and Manufacture,  Vol. 41, No. 12, (2001), 1795-1814.
12.   Gupta, M. and Kumar, S., "Investigation of surface roughness and mrr for turning of UD-GFRP using pca and taguchi method", Engineering Science and Technology, an International Journal,  Vol. 18, No. 1, (2015), 70-81.
13.   Azmi, A., Lin, R.J. and Bhattacharyya, D., "Tool wear prediction models during end milling of glass fibre-reinforced polymer composites", The International Journal of Advanced Manufacturing Technology, (2013), 1-18.
14.   Rahman, M., Ramakrishna, S., Prakash, J. and Tan, D., "Machinability study of carbon fiber reinforced composite", Journal of Materials Processing Technology,  Vol. 89, (1999), 292-297.
15.   Standard, A., "Standard test method for ignition loss of cured reinforced resin", West Conshohocken (PA): ASTM,  Vol. 100.
16.   Pecat, O., Rentsch, R. and Brinksmeier, E., "Influence of milling process parameters on the surface integrity of CFRP", Procedia CIRP,  Vol. 1, (2012), 466-470.
17.   Langari, J., Kolahan, F. and Aliakbari, K., "Effect of tool speed on axial force, mechanical properties and weld morphology of friction stir welded joints of a7075-t651", International Journal of Engineering,  Vol. 29, (2016).
18.   Sakuma, K. and Seto, M., "Tool wear in cutting glass-fiber-reinforced plastics: The relation between fiber orientation and tool wear", Bulletin of JSME,  Vol. 26, No. 218, (1983), 1420-1427.