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Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques

Year 2012, Volume: 1 Issue: 2, 95 - 109, 27.03.2016

Abstract

The thrust force and surface roughness of plain carbide drill (K20) with drill parameters (drill diameter, spindle speed and feed rate) in drilling carbon fibre reinforced plastic (CFRP) laminate/aluminum (Grade 2024) stack was experimentally investigated in this study. A L27 orthogonal array and signal-to-noise (S/N) were employed to analyze the effect of drill parameters. Using Taguchi method for design of a robust experiment, the interactions among factors are also investigated. The analysis of variance (ANOVA) shows that the feed rate and drill diameter are the most significant parameters to the overall performance while drilling CFRP/al stack. These results are in good agreement with Signal/Noise (S/N) ratio of Taguchi analysis. Hole diameter of CFRP is found to be less (10μm) than the nominal diameter of drill. Circularity is found to be around 6μm at low feed rates in CFRP. When the feed is increased, the circularity increases to 25 μm.

References

  • Abrate S.Machining of composites. Composites Engineering Handbook, Marcel Deckker Inc., 1997: 777 – 807.
  • Chen WC. Some experimental investigations in the drilling of carbon fibre reinforced composite laminations. Int. J. Mach. Tools and Mfr., 1997; 37(8): 1097 – 1108.
  • Konig W, Cronjager L, Spur G and Tonshoff HK. Machining of new materials. Annals of the CIRP, 1990; 39(2): 673 – 680.
  • Komanduri R. Machining of fibre reinforced composites. Mach. Sc. and Tech., 1997; 1(1): 113 – 152.
  • Bhatnagar N, Ramakrishnan N, Naik NK and Komanduri R. On the machining of fiber reinforced plastic composite laminates. Int. J. Mach. Tools Mfr., 1995; 35(5): 701 – 716.
  • Zitoune R, Collombet F, Lachaud F, Piquet R and Pasquet P. Experiment- calculation comparison of the cutting conditions representative of the long fibre composite drilling phase. Comp. Sc. and Tech., 2005; 65(3-4): 455 – 466.
  • Hocheng H and Dharan CKH. Delamination during drilling in composite laminates. Trans. ASME, 1990; 112: 236 – 239.
  • Zitoune R. Collombet F. Numerical Prediction of the thrust force responsible of delamination during drilling of the long fibre composite structures. Comp. Part A: Apld. Sc. and Manuf., 2007; 38: 858 – 860.
  • Zitoune R, Collombet F and Hernaiz Lopez G. Experimental and analytical study of the influence of HexFit® glass fibre composite manufacturing process on delamination during drilling. Int. J. of Mach. and Machinability of Matls., 2008; 3(3-4): 326 – 342.
  • Tsao CC and Hocheng H. Taguchi analysis of delamination associated with various drill bits in drilling of composite materials. Int. J. of Mc Tools & Mafr., 2004; 44: 1085 – 1090.
  • Krishnaraj V, Vijayarangan S and Paulo Davim. An experimental and statistical study on the effect of drill geometries on force and hole quality in drilling of glass fiber reinforced plastic. Int. J. of Materials and Product Technology, 2008; 32(2-3): 264 – 275.
  • Mohan NS, Ramachandra A and Kulkarni SM. Influence of process parameters on cutting force and torque during drilling of glass-fibre polyester reinforced composites. Comp. Structures, 2005; 71: 407 – 413.
  • Davim JP, Pedro R and Conceicao A. Experimental study of drilling glass fiber reinforced (GFRP) manufactured by hand lay-up. Comp. Science and Tech., 2004; 64: 289 – 297.
  • List G, Nouari M, G´ehin D, Gomez S, Manaud P, Le Petitcorps Y and Girot F. Wear behaviour of cemented carbide tools in dry machining of aluminum alloy. Wear, 2005; 259: 1177 – 1189.
  • Nouari M. List G. Girot F. Ge´hin G. Effect of machining parameters and coating on wear mechanisms in dry drilling of aluminum alloys. Int. J. of Machine Tools & Mafr., 2005; 45: 1436 – 1442.
  • Rivero A, Aramendi G, Herranz S and Lopez de Lacalle LN. An experimental investigation of the effect of coatings and cutting parameters on the dry drilling performance of aluminum alloys. Int J Adv Manuf Technol, 2006; 28: 1 – 11.
  • Batzer SA, Haan DM, Rao PD, Olson WW and Sutherland JW. Chip morphology and hole surface texture in the drilling of cast aluminum alloys. J. of Materials Processing Tech., 1998; 79: 72 – 78.
  • Brinksmeier E and Janssen R. Drilling of multi-layer composite materials consisting of carbon fiber reinforced plastics (CFRP), titanium and aluminum alloys. Annals of the CIRP, 2002; 51(1): 87 – 90.
  • Ramulu M, Branson T and Kim D. A study on the drilling of composite and titanium stacks. Composite Structures, 2001; 54: 67 – 77.
  • Kim D and Ramulu M. Drilling process optimization for graphite/bismaleimide- titanium alloy stacks. Composite Structures, 2004; 63(1): 101 – 114.
  • Kim D and Ramulu M. Machinability of titanium/graphite hybrid composites in drilling. Trans. NAMRI/SME., 2005; 33: 445 – 452.
  • Kim D and Ramulu M. Study on the drilling of titanium/graphite hybrid composites. J Eng Mater Technol., 2007; 129(3): 390 – 397.
  • Roudge M, Cherif M, Cahuc O, Darnis P and Danis M. Multi-layers materials, qualitative approach of the process. Int J Materials Forming, 2008; 1(1): 949 – 952.
  • Denkena B, Boehnke D and Dege JH. Helical milling of CFRP–titanium layer compounds. CIRP Journal of Manufacturing Science and Technology, 2008; 1: 64 – 69.
  • Mike T. Composites challenge cutting tools. Manufacturing Engineering, 2007; 138(4).
  • Bagci E and Ozcelik B. Analysis of temperature changes on the twist drill under different drilling conditions based on Taguchi method during dry drilling of Al7075-T651. Int J Adv Manuf Tech., 2006; 29(7-8): 629 – 636.

Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques

Year 2012, Volume: 1 Issue: 2, 95 - 109, 27.03.2016

Abstract

The thrust force and surface roughness of plain carbide drill (K20) with drill parameters (drill diameter, spindle speed and feed rate) in drilling carbon fibre reinforced plastic (CFRP) laminate/aluminum (Grade 2024) stack was experimentally investigated in this study. A L27 orthogonal array and signal-to-noise (S/N) were employed to analyze the effect of drill parameters. Using Taguchi method for design of a robust experiment, the interactions among factors are also investigated. The analysis of variance (ANOVA) shows that the feed rate and drill diameter are the most significant parameters to the overall performance while drilling CFRP/al stack. These results are in good agreement with Signal/Noise (S/N) ratio of Taguchi analysis. Hole diameter of CFRP is found to be less (10μm) than the nominal diameter of drill. Circularity is found to be around 6μm at low feed rates in CFRP. When the feed is increased, the circularity increases to 25 μm.

References

  • Abrate S.Machining of composites. Composites Engineering Handbook, Marcel Deckker Inc., 1997: 777 – 807.
  • Chen WC. Some experimental investigations in the drilling of carbon fibre reinforced composite laminations. Int. J. Mach. Tools and Mfr., 1997; 37(8): 1097 – 1108.
  • Konig W, Cronjager L, Spur G and Tonshoff HK. Machining of new materials. Annals of the CIRP, 1990; 39(2): 673 – 680.
  • Komanduri R. Machining of fibre reinforced composites. Mach. Sc. and Tech., 1997; 1(1): 113 – 152.
  • Bhatnagar N, Ramakrishnan N, Naik NK and Komanduri R. On the machining of fiber reinforced plastic composite laminates. Int. J. Mach. Tools Mfr., 1995; 35(5): 701 – 716.
  • Zitoune R, Collombet F, Lachaud F, Piquet R and Pasquet P. Experiment- calculation comparison of the cutting conditions representative of the long fibre composite drilling phase. Comp. Sc. and Tech., 2005; 65(3-4): 455 – 466.
  • Hocheng H and Dharan CKH. Delamination during drilling in composite laminates. Trans. ASME, 1990; 112: 236 – 239.
  • Zitoune R. Collombet F. Numerical Prediction of the thrust force responsible of delamination during drilling of the long fibre composite structures. Comp. Part A: Apld. Sc. and Manuf., 2007; 38: 858 – 860.
  • Zitoune R, Collombet F and Hernaiz Lopez G. Experimental and analytical study of the influence of HexFit® glass fibre composite manufacturing process on delamination during drilling. Int. J. of Mach. and Machinability of Matls., 2008; 3(3-4): 326 – 342.
  • Tsao CC and Hocheng H. Taguchi analysis of delamination associated with various drill bits in drilling of composite materials. Int. J. of Mc Tools & Mafr., 2004; 44: 1085 – 1090.
  • Krishnaraj V, Vijayarangan S and Paulo Davim. An experimental and statistical study on the effect of drill geometries on force and hole quality in drilling of glass fiber reinforced plastic. Int. J. of Materials and Product Technology, 2008; 32(2-3): 264 – 275.
  • Mohan NS, Ramachandra A and Kulkarni SM. Influence of process parameters on cutting force and torque during drilling of glass-fibre polyester reinforced composites. Comp. Structures, 2005; 71: 407 – 413.
  • Davim JP, Pedro R and Conceicao A. Experimental study of drilling glass fiber reinforced (GFRP) manufactured by hand lay-up. Comp. Science and Tech., 2004; 64: 289 – 297.
  • List G, Nouari M, G´ehin D, Gomez S, Manaud P, Le Petitcorps Y and Girot F. Wear behaviour of cemented carbide tools in dry machining of aluminum alloy. Wear, 2005; 259: 1177 – 1189.
  • Nouari M. List G. Girot F. Ge´hin G. Effect of machining parameters and coating on wear mechanisms in dry drilling of aluminum alloys. Int. J. of Machine Tools & Mafr., 2005; 45: 1436 – 1442.
  • Rivero A, Aramendi G, Herranz S and Lopez de Lacalle LN. An experimental investigation of the effect of coatings and cutting parameters on the dry drilling performance of aluminum alloys. Int J Adv Manuf Technol, 2006; 28: 1 – 11.
  • Batzer SA, Haan DM, Rao PD, Olson WW and Sutherland JW. Chip morphology and hole surface texture in the drilling of cast aluminum alloys. J. of Materials Processing Tech., 1998; 79: 72 – 78.
  • Brinksmeier E and Janssen R. Drilling of multi-layer composite materials consisting of carbon fiber reinforced plastics (CFRP), titanium and aluminum alloys. Annals of the CIRP, 2002; 51(1): 87 – 90.
  • Ramulu M, Branson T and Kim D. A study on the drilling of composite and titanium stacks. Composite Structures, 2001; 54: 67 – 77.
  • Kim D and Ramulu M. Drilling process optimization for graphite/bismaleimide- titanium alloy stacks. Composite Structures, 2004; 63(1): 101 – 114.
  • Kim D and Ramulu M. Machinability of titanium/graphite hybrid composites in drilling. Trans. NAMRI/SME., 2005; 33: 445 – 452.
  • Kim D and Ramulu M. Study on the drilling of titanium/graphite hybrid composites. J Eng Mater Technol., 2007; 129(3): 390 – 397.
  • Roudge M, Cherif M, Cahuc O, Darnis P and Danis M. Multi-layers materials, qualitative approach of the process. Int J Materials Forming, 2008; 1(1): 949 – 952.
  • Denkena B, Boehnke D and Dege JH. Helical milling of CFRP–titanium layer compounds. CIRP Journal of Manufacturing Science and Technology, 2008; 1: 64 – 69.
  • Mike T. Composites challenge cutting tools. Manufacturing Engineering, 2007; 138(4).
  • Bagci E and Ozcelik B. Analysis of temperature changes on the twist drill under different drilling conditions based on Taguchi method during dry drilling of Al7075-T651. Int J Adv Manuf Tech., 2006; 29(7-8): 629 – 636.
There are 26 citations in total.

Details

Primary Language Turkish
Journal Section Articles
Authors

Vijayan Krishnaraj This is me

Redouane Zitoune This is me

Francis Collombet - This is me

Publication Date March 27, 2016
Published in Issue Year 2012 Volume: 1 Issue: 2

Cite

APA Krishnaraj, V., Zitoune, R., & -, F. C. (2016). Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques. Usak University Journal of Material Sciences, 1(2), 95-109.
AMA Krishnaraj V, Zitoune R, - FC. Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques. Usak University Journal of Material Sciences. March 2016;1(2):95-109.
Chicago Krishnaraj, Vijayan, Redouane Zitoune, and Francis Collombet -. “Study of Drilling of Multi-Material (CFRP/Al) Using Taguchi and Statistical Techniques”. Usak University Journal of Material Sciences 1, no. 2 (March 2016): 95-109.
EndNote Krishnaraj V, Zitoune R, - FC (March 1, 2016) Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques. Usak University Journal of Material Sciences 1 2 95–109.
IEEE V. Krishnaraj, R. Zitoune, and F. C. -, “Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques”, Usak University Journal of Material Sciences, vol. 1, no. 2, pp. 95–109, 2016.
ISNAD Krishnaraj, Vijayan et al. “Study of Drilling of Multi-Material (CFRP/Al) Using Taguchi and Statistical Techniques”. Usak University Journal of Material Sciences 1/2 (March 2016), 95-109.
JAMA Krishnaraj V, Zitoune R, - FC. Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques. Usak University Journal of Material Sciences. 2016;1:95–109.
MLA Krishnaraj, Vijayan et al. “Study of Drilling of Multi-Material (CFRP/Al) Using Taguchi and Statistical Techniques”. Usak University Journal of Material Sciences, vol. 1, no. 2, 2016, pp. 95-109.
Vancouver Krishnaraj V, Zitoune R, - FC. Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques. Usak University Journal of Material Sciences. 2016;1(2):95-109.