Experimental Investigation of the Machinability of Basalt Fiber Reinforced Epoxy Matrix Composites and the Effect of Nanoparticle Additives on Machining Quality

Mehmet Tongur; Necati Ataberk

Experimental Investigation of the Machinability of Basalt Fiber Reinforced Epoxy Matrix Composites and the Effect of Nanoparticle Additives on Machining Quality

Abstract

In this study, basalt fiber-reinforced epoxy matrix composite materials were produced using hand lay-up and vacuum infusion methods, both in their unreinforced form and with the addition of 0.25 wt% MWCNT and 0.5 wt% h-BN nanoparticles. Additionally, hybrid basalt fiber-reinforced epoxy matrix composites were manufactured by keeping the MWCNT content constant at 0.25 wt% while varying the h-BN reinforcement levels to 0.25 wt%, 0.5 wt%, and 0.75 wt%. The effects of nanoparticle reinforcement, cutting speed, and feed rate on parameters such as cutting force, delamination, and average surface roughness (Ra) during drilling processes were investigated. Among the cutting forces observed, the lowest thrust forces during drilling were achieved for all samples at a feed rate of 300 mm/min and a spindle speed of 4800 rpm. When comparing reinforcement levels, the lowest cutting force values were obtained in sample N5, which contained the highest h-BN nanoparticle reinforcement. In terms of surface roughness, the lowest value of 0.95 μm was achieved for sample N5 at a feed rate of 300 mm/min and a spindle speed of 4800 rpm during the drilling process. Regarding delamination, it was observed that increasing h-BN content, combined with low feed rates and high spindle speeds, reduced delamination damage in both drilling and milling processes.

Keywords

Basalt fiber fabric , MWCNT nanoparticles , Delamination damage , Hexagonal boron nitride nanoparticles , Surface roughness , Drilling

References

[1] M. Kishore, M. Amrita, and B. Kamesh, "Experimental investigation of milling on basalt-jute hybrid composites with graphene as nanofiller," Materials Today: Proceedings, vol. 43, pp. 726–730, Jan. 2021. doi: 10.1016/j.matpr.2020.12.847
[2] K. K. Chawla, Composite materials: Science and engineering, third edition, New York: Springer, 2012. doi: 10.1007/978-0-387-74365-3
[3] D. Matykiewicz, M. Barczewski, D. Knapski, and K. Skórczewska, "Hybrid effects of basalt fibers and basalt powder on thermomechanical properties of epoxy composites," Composites Part B: Engineering, vol. 125, pp. 157–164, Sep. 2017. doi: 10.1016/j.compositesb.2017.05.060
[4] K. El-Ghaoui, J. F. Chatelain, and C. Ouellet-Plamondon, "Effect of Graphene on Machinability of Glass Fiber Reinforced Polymer (GFRP)," Journal of Manufacturing and Materials Processing, vol. 3, no. 3, p. 78, Sep. 2019. doi: 10.3390/jmmp3030078
[5] Y. H. Çelik, E. Kilickap, and A. İ. Kilickap, "An experimental study on milling of natural fiber (jute)- reinforced polymer composites," Journal of Composite Materials, vol. 53, no. 22, pp. 3127–3137, Sep. 2019. doi: 10.1177/0021998319826373
[6] F. Javanshour et al., "Effect of graphene oxide surface treatment on the interfacial adhesion and the tensile performance of flax epoxy composites," Composites Part A: Applied Science and Manufacturing, vol. 142, p. 106270, Mar. 2021. doi: 10.1016/j.compositesa.2020.106270
[7] F. B. Gumus, F. Ceritbinmez, and A. Yapici, "The effect of hexagonal nano boron nitride on mechanical performances and machinability behaviors of basalt fabric reinforced epoxy composites," Proceedings of Materials Science and Engineering, vol. 235, no. 23, pp. 7161–7168, May 2021. doi: 10.1177/09544062211013374
[8] S. Morkavuk, K. Aslantaş, L. Gemi, U. Köklü, and Ş. Yazman, "The influence of drilling-induced damages and hole quality on hoop tensile and fatigue behavior of CFRP tubes," Composites Part A: Applied Science and Manufacturing, vol. 179, p. 108005, Apr. 2024. doi: 10.1016/j.compositesa.2024.108005
[9] Ş. Yazman, L. Gemi, S. Morkavuk, and U. Köklü, "Investigation of the effect of symmetrical hybrid stacking on drilling machinability of unidirectional CFRP, GFRP and hybrid composites: Drilling tests and damage analysis," Composites Part A: Applied Science and Manufacturing, vol. 187, p. 108486, Dec. 2024. doi: 10.1016/j.compositesa.2024.108486
[10] F. Turan, "The effect of MWCNT concentration on the electrical resistance change characteristic of glass/fiber epoxy composites under low cycle fatigue loading," Materials Testing, vol. 67, no. 1, pp. 1–16, Jan. 2025. doi: 10.1515/mt-2024-0107

[11] N. Geier, J. P. Davim, and T. Szalay, "Advanced cutting tools and technologies for drilling carbon fibre reinforced polymer (CFRP) composites: A review," Composites Part A: Applied Science and Manufacturing, vol. 125, p. 105552, Oct. 2019. doi: 10.1016/j.compositesa.2019.105552
[12] S. Margabandu and S. Subramaniam, "An experimental investigation of thrust force, delamination and surface roughness in drilling of jute/carbon hybrid composites," World Journal of Engineering, vol. 17, no. 5, pp. 661–674, Jul. 2020. doi: 10.1108/WJE-03-2020-0080
[13] T. Gao et al., "Carbon fiber reinforced polymer in drilling: From damage mechanisms to suppression," Composite Structures, vol. 286, p. 115232, Apr. 2022. doi: 10.1016/j.compstruct.2022.115232
[14] N. Deshpande, H. Vasudevan, and R. Rajguru, "Experimental investigation and optimization of milling parameters in the machining of NEMA G-11 GFRP composite material using PCD tool," in Proc. 5th International and 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014), Guwahati, India, Dec. 2014, pp. 2105–2114.
[15] M. Ramesh and A. Gopinath, "Measurement and analysis of thrust force in drilling sisal-glass fiber reinforced polymer composites," in IOP Conference Series: Materials Science and Engineering, vol. 197, May 2017, p. 012056. doi: 10.1088/1757-899X/197/1/012056
[16] H. Ejaz, A. Mubashar, M. A. M, and S. Waqar, "Effect of GNP and MWCNT Addition on Lap Shear Strength of Adhesively Bonded Joints," in 2022 19th International Bhurban Conference on Applied Sciences and Technology, Islamabad, Pakistan, Aug. 15–17, 2022, pp. 116–121. Piscataway, NJ: IEEE, 2022. doi: 10.1109/IBCAST54850.2022.9990107
[17] Ş. Yazman, "Investigation of the Mechanical Properties of Hybrid Nanocomposite Adhesives Reinforced with Carbon Nanotube and Ceramic Nanoparticles," Ph.D. dissertation, Institute of Science, Necmettin Erbakan University, Konya, Turkey, 2018.
[18] M. Tongur, "Experimental Investigation of the Mechanical and Thermal Properties of Nanoparticle-Modified Polyurethane Adhesives," M.Sc. thesis, Department of Mechanical Engineering, Institute of Science, Necmettin Erbakan University, Konya, Turkey, 2020.
[19] G. Bahtiyar, M. Ekrem, B. Ünal, and S. Ak, "Mechanical Properties and Damage Behaviours of Polyurethane Composites Reinforced With BNNP and MWCNT Hybrid Nanoparticles," Journal of Elastomers and Plastics, vol. 55, no. 4, pp. 613–625, Mar. 2023. doi: 10.1177/00952443231165427
[20] P. KumarKharwar, R. KumarVerma, and A. Singh, "Simultaneous optimisation of quality and productivity characteristics during machining of multiwall carbon nanotube/epoxy nanocomposites," 2020. doi: 10.1080/14484846.2020.1794511
[21] S. Morkavuk, "Investigation of the Effect of Drilling Process on the Mechanical and Fatigue Behavior of Carbon Fiber Reinforced Composite Tubes," Ph.D. dissertation, Afyon Kocatepe University, Afyon, Turkey, 2023.
[22] Y. H. Çelik, E. Kilickap, and N. Koçyiğit, "Evaluation of drilling performances of nanocomposites reinforced with graphene and graphene oxide," International Journal of Advanced Manufacturing Technology, vol. 100, no. 9, pp. 2371–2385, 2018. doi: 10.1007/s00170-018-2875-Z
[23] U. A. Khashaba, "A novel approach for characterization of delamination and burr areas in drilling FRP composites," Composite Structures, vol. 290, p. 115534, Jun. 2022. doi: 10.1016/j.compstruct.2022.115534
[24] H. B. Upputuri and V. S. Nimmagadda, "Optimization of drilling process parameters used in machining of glass fiber reinforced epoxy composite," Materials Today: Proceedings, vol. 23, pp. 594–599, 2020. doi: 10.1016/j.matpr.2019.05.415
[25] A. Can, "Study on the machinability of SMC composites during hole milling: Influence of tool geometry and machining parameters," Arabian Journal for Science and Engineering, vol. 44, no. 4, pp. 7599–7616, Apr. 2019. [Online]. Available: https://link.springer.com/article/10.1007/s13369-019-03865-z. [Accessed: 25-Jun-2025]
[26] K. K. Panchagnula and K. Palaniyandi, "Drilling on fiber reinforced polymer/nanopolymer composite laminates: a review," Journal of Materials Research and Technology, vol. 7, no. 2, pp. 180–189, 2018. doi: 10.1016/j.jmrt.2017.06.003
[27] K. Xiao and L. Zhang, "The role of viscous deformation in the machining of polymers," International Journal of Mechanical Sciences, vol. 44, no. 11, pp. 2317–2336, Nov. 2002. doi: 10.1016/S0020-7403(02)00178-9
[28] J. Samuel, A. Dikshit, R. E. DeVor, S. G. Kapoor, and K. J. Hsia, "Effect of Carbon Nanotube (CNT) Loading on the Thermomechanical Properties and the Machinability of CNT-Reinforced Polymer Composites," Journal of Manufacturing Science and Engineering, vol. 131, no. 3, Jun. 2009. doi: 10.1115/1.3123337
[29] S. Madarvoni and R. P. S. Sreekanth, "Mechanical Characterization of Graphene—Hexagonal Boron Nitride-Based Kevlar–Carbon Hybrid Fabric Nanocomposites," Polymers (Basel), vol. 14, no. 13, 2022. doi: 10.3390/polym14132559
[30] D. Geng, X. Chen, L. Fang, ve H. Wang, "Delamination formation, evaluation and suppression during drilling of composite laminates: A review," Composite Structures, vol. 216, pp. 168–186, May 2019. doi: 10.1016/j.compstruct.2019.02.099
[31] C. Guo, H. Zhang, ve Y. Wang, "Mechanical and thermal properties of multiwalled carbon-nanotube-reinforced Al₂O₃ nanocomposites," Ceramics International, cilt. 46, ss. 17,449–17,460, 2020. doi: 10.1016/j.ceramint.2020.04.039
[32] Z. Li, J. Ma, H. Ma, and X. Xu, "Properties and Applications of Basalt Fiber and Its Composites," in IOP Conference Series: Earth and Environmental Science, Institute of Physics Publishing, Oct. 2018. doi: 10.1088/1755-1315/186/2/012052
[33] V. N. Gaitonde, S. R. Karnik, J. C. Rubio, A. E. Correia, A. M. Abrão, and J. P. Davim, "Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites," Journal of Materials Processing Technology, vol. 203, no. 1–3, 2008. doi: 10.1016/j.jmatprotec.2007.10.050
[34] S. R. Karnik, V. N. Gaitonde, J. C. Rubio, A. E. Correia, A. M. Abrão, and J. P. Davim, "Delamination analysis in high speed drilling of carbon fiber reinforced plastics (CFRP) using artificial neural network model," Materials & Design, vol. 29, no. 9, pp. 1768–1776, 2008. doi: 10.1016/j.matdes.2008.03.014
[35] A. A. Abdul Nasir, A. I. Azmi, and A. N. M. Khalil, "Measurement and optimisation of residual tensile strength and delamination damage of drilled flax fibre reinforced composites," Measurement, vol. 75, 2015. doi: 10.1016/j.measurement.2015.07.046
[36] K. R. Sumesh and K. Kanthavel, "Abrasive water jet machining of Sisal/Pineapple epoxy hybrid composites with the addition of various fly ash filler," Materials Research Express, vol. 7, no. 3, p. 035303, Mar. 2020. doi: 10.1088/2053-1591/ab7865
[37] K. Bhowmik, S. K. Basantia, T. Roy, A. Bandyopadhyay, N. Khutia, and A. R. Chowdhury, "Mechanical Properties of MWCNT Reinforced Epoxy Nanocomposites: Experimental, Micromechanical and Numerical Study," Journal of the Institution of Engineers (India): Series D, vol. 103, no. 2, pp. 575–586, Dec. 2022. doi: 10.1007/s40033-022-00358-6
[38] R. Farshbaf Zinati, M. R. Razfar, and H. Nazockdast, "Surface Integrity Investigation for Milling PA 6/MWCNT," Materials and Manufacturing Processes, vol. 30, no. 8, pp. 1035–1041, Aug. 2015. doi: 10.1080/10426914.2014.961473
[39] R. K. Verma, V. K. Singh, D. K. Singh, and P. K. Kharwar, "Experimental investigation on surface roughness and circularity error during drilling of polymer nanocomposites," Materials Today: Proceedings, vol. 44, pp. 2501–2506, 2021. doi: 10.1016/j.matpr.2020.12.597

Details

Primary Language

English

Subjects

Mechanical Engineering (Other)

Journal Section

Research Article

Authors

Mehmet Tongur ^*
0000-0002-5847-3295
Türkiye

Necati Ataberk
0000-0002-5394-9549
Türkiye

Publication Date

August 31, 2025

Submission Date

May 6, 2025

Acceptance Date

August 18, 2025

Published in Issue

Year 2025 Volume: 11 Number: 2

IZ

https://izlik.org/JA94AC62TX

IEEE

[1]M. Tongur and N. Ataberk, “Experimental Investigation of the Machinability of Basalt Fiber Reinforced Epoxy Matrix Composites and the Effect of Nanoparticle Additives on Machining Quality”, GJES, vol. 11, no. 2, pp. 274–290, Aug. 2025, [Online]. Available: https://izlik.org/JA94AC62TX

GJES is indexed and archived by:

33113 33114 33115 33116 33117

Gazi Journal of Engineering Sciences (GJES) publishes open access articles under a Creative Commons Attribution 4.0 International License (CC BY)