CUTTING TOOL GEOMETRY IN THE DRILLING OF CFRP COMPOSITE PLATES AND TAGUCHI OPTIMISATION OF THE CUTTING PARAMETERS AFFECTING DELAMINATION

Abstract

It is possible to improve the hole quality by reducing the delamination which occurs in the drilling of carbon fibre reinforced plastic (CFRP) composite plates. For this study, carried out under dry machining conditions, the parameters included three different cutting speeds, three different feed rates and drill geometry involving three different point angles. The Taguchi L9 orthogonal array experimental design was selected and the optimum cutting parameters and drill geometry for reducing the damage factor to a minimum were determined. The optimum test conditions were achieved using the parameter combination of 118° point angle, 30 m/min cutting speed and 0.06 mm/rev feed rate (A1B1C1). In addition, variance analysis (ANOVA) was conducted to determine the effect rate of the parameters on the damage factor. The variable having the greatest effect on the damage factor was found to be the point angle (47.66%), followed by the cutting speed (24.44%) and feed rate (19.82%). The conditions for minimising delamination damage in the drilling of the CFRP plates were optimised successfully by using the Taguchi test design.

Keywords

• CFRP composite
• drilling
• delamination
• design of experiments
• ANOVA

References

1. [1] Kara F., (2017) Taguchi optimization of surface roughness and flank wear during the turning of DIN 1.2344 tool steel, Materials Testing 59 (10), 903–908.
2. [2] Kara F., Çiçek A., Demir H., (2013) Multiple Regression and ANN Models for Surface Quality of Cryogenically-Treated AISI, 52100 Bearing Steel, J. Balkan Tribol. Assoc. 19 (4), 570–584.
3. [3] Günay M., Yücel E., (2013) Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron, Measurement 46 (2), 913–919.
4. [4] Ayyıldız M., Çetinkaya K., (2016) Comparison of four different heuristic optimization algorithms for the inverse kinematics solution of a real 4-DOF serial robot manipulator, Neural Computing and Applications 27 (4), 825–836.
5. [5] Davim J.P., Reis P., (2003) Study of delamination in drilling carbon fiber reinforced plastics (CFRP) using design experiments Composite Structures 59, 481–487.
6. [6] Abhishek K., Datta S., Mahapatra, S.S., (2017) Optimization of MRR, Surface Roughness, and Maximum Tool-Tip Temperature during Machining of CFRP Composites, Materials Today: Proceedings 4, 2761–2770.
7. [7] Aravind S., Shunmugesh K., Biju J., Vijayan J.K., (2017) Optimization of Micro-Drilling Parameters by Taguchi Grey Relational Analysis, Materials Today: Proceedings 4, 4188–4195.
8. [8] Shunmugesh K., Panneerselvam K., (2017) Grey Relational Analysis Based Optimization Of Multiple Responses in Drilling Of Carbon Fiber-Epoxy Composites, Materials Today: Proceedings 4, 2861–2870.

9. [9] Tsao C.C., Chiu Y.C., (2011) Evaluation of drilling parameters on thrust force in drilling carbon fiber reinforced plastic (CFRP) composite laminates using compound core-special drills, International Journal of Machine Tools & Manufacture 51, 740–744.
10. [10] Iliescu D., Gehin D., Gutierrez M.E., Girot F., (2010) Modeling and tool wear in drilling of CFRP, International Journal of Machine Tools & Manufacture 50, 204–213.
11. [11] Karpat Y., Değer B., Bahtiyar O., (2012) Drilling thick fabric woven CFRP laminates with double point angle drills, Journal of Materials Processing Technology 212, 2117– 2127.
12. [12] Gaitonde V.N., Karnik S.R., Campos Rubio J., Esteves Correia A., Abrão, A.M., Paulo Davim J., (2011) A study aimed at minimizing delamination during drilling of CFRP composites, Journal of Composite.Material 45, 2359–2368.
13. [13] Savaşkan M., Taptık Y., Ürgen M.., (2004) Deney tasarımı yöntemi ile matkap uçlarında performans optimizasyonu, İtü dergisi /d mühendislik 3 (6), 117-128.
14. [14] Turgut E., Dikici A., (2011) Optimization of design parameters of co-axial heat exchanger with Taguchi method, 6th International Advanced Technologies Symposium (IATS’11), Elazığ, Turkey, 278–281.
15. [15] Sakarya N., Göloğlu C., (2006) Determination of Cutter Path Strategıes and Cuttıng Parameters Effects on Surface Roughness in Pocket Milling by Taguchı Method, J. Fac. Eng. Arch. Gazi Univ. 21 (4), 603–611.
16. [16] Karabatak M., Kara F., (2016) AISI D2 Soğuk İş Takım Çeliğinin Sert Tornalanmasında Yüzey Pürüzlülüğünün Deneysel Optimizasyonu, Journal of Polytechnic 19 (3), 349–355.