Investigation of drilling performance and mechanical properties of unfilled and hybrid composites

Yıl 2025, Cilt: 14 Sayı: 1, 1 - 1

Hüseyin Gürbüz , Şehmus Baday , Mehmet Emin Demir , İbrahim Halil Akcan

https://doi.org/10.28948/ngumuh.1571365

Öz

The properties and ratios of filler and reinforcement particles in composite materials affect the mechanical properties of composite materials such as tensile and flexural. In addition, the drilling process is of great importance for the assembly and connections of composite materials. Therefore, delaminations and feed forces that occur in drilling composite materials at different machining parameters have been the subject of many studies. The aim of this study is to investigate the effects of adding Gr and B4C fillers to carbon fiber-reinforced composites on the mechanical properties and machinability of the composites. Tensile and flexural strengths of the composites, produced using hand lay-up method with 7.5% B4C and 7.5% Gr fillers, were determined. It was found that the filler particles reduced the tensile strength of the composites but increased their flexural strength. Through-hole drilling was applied to composite workpieces at 4 different feed rates and cutting speeds. Additionally, the effects of machining parameters such as feed rate and cutting speed on thrust force and delamination factor during the drilling of both unfilled and hybrid-filled composites were examined. While an increase in feed rate positively affected the delamination factor, an increase in cutting speed had a negative impact. Moreover, the addition of fillers to carbon fiber reinforcement reduced the amount of delamination but increased the thrust forces.

Anahtar Kelimeler

Mechanical properties, Drilling, Delamination, Carbon Fiber, B4C, Gr

Proje Numarası

BTÜBAP-2021-YL-020

Dolgusuz ve hibrit kompozitlerin delme performansının ve mekanik özelliklerinin incelenmesi

Öz

Kompozit malzemelerin içerdiği dolgu ve takviye parçacıklarının özellikleri ve oranları kompozit malzemelerin çekme ve eğme gibi mekanik özelliklerini etkilemektedir. Ayrıca kompozit malzemelerin montaj ve bağlantıları için delme işlemi büyük bir önem arz etmektedir. Bu yüzden farklı işleme parametrelerde kompozit malzemelerin delinmesinde meydana gelen delaminasyonlar ve ilerleme kuvvetleri birçok araştırmaya konu olmuştur. Bu çalışmanın amacı Gr ve B4C dolgularının karbon elyaf takviyeli kompozitlere ilave ederek dolguların kompozitin mekanik özellikleri ve işlenebilirliği üzerindeki etkilerini araştırmaktadır. El yatırma yöntemiyle %7.5 B4C ve %7.5 Gr dolguları kullanılarak üretilen kompozitlerin çekme ve eğilme dayanımları belirlenmiştir. Dolgu parçacıklarının kompozitin çekme dayanımını düşürdüğü, eğilme dayanımını ise arttırdığı anlaşılmıştır. Kompozit iş parçalarına 4 farklı ilerleme oranı ve kesme hızında boydan boya delik delme işlemi uygulanmıştır. Ayrıca dolgusuz ve hibrit dolgulu kompozitlerin delinmesinde ilerleme oranı ve kesme hızı gibi işleme parametrelerinin ilerleme kuvveti ve delaminasyon faktörü üzerindeki etkisi incelenmiştir. İlerleme oranının artması delaminasyon faktörünü olumlu etkilerken, kesme hızının artması olumsuz etkilemektedir. Karbon elyaf takviyesine dolgu ilave edilmesi ise delaminasyon miktarını düşürmüş, ilerleme kuvvetlerini ise arttırmıştır.

Anahtar Kelimeler

Mekanik özellikler, Delme, Delaminasyon, Karbon Elyaf, B4C, Gr

Proje Numarası

BTÜBAP-2021-YL-020

Teşekkür

Yazarlar, bu deneysel çalışmanın gerçekleştirilmesinde her türlü katkı ve desteklerini sağlayan Batman Üniversitesi BAP birimine (BTÜBAP-2021-YL-020 no’lu proje) teşekkür eder.

Kaynakça

• J. X. Chan, J. F. Wong, M. Petrů, A. Hassan, U. Nirmal, N. Othman and R. A. Ilyas, Effect of nanofillers on tribological properties of polymer nanocomposites: A review on recent development. Polymers, 13 (17), 2867, 2021. https://doi.org/10.3390/polym13172867.
• S. Basavarajappa, A. G. Joshi, K. Arun, A. P. Kumar and M. P. Kumar, Three-body abrasive wear behaviour of polymer matrix composites filled with SiC particles. Polymer-Plastics Technology and Engineering, 49 (1), 8-12, 2009. https://doi.org/10.1080/03602550903206407.
• G. Divya, and B. Suresha, Role of metallic nanofillers on mechanical and tribological behaviour of carbon fabric reinforced epoxy composites. Materials Sciences and Applications, 9 (9), 740-750, 2018. https://doi.org/10.4236/msa.2018.99054.
• H. Rajashekaraiah, S. Mohan, P. K. Pallathadka, and S. Bhimappa, Dynamic mechanical analysis and three‐body abrasive wear behaviour of thermoplastic copolyester elastomer composites. Advances in Tribology, 2014 (1), 210187, 2014. https://doi.org/10.1155/2014/210187.
• S. Shahabaz, P. Mehrotra, H. Kalita, S. Sharma, N. Naik, D. J. Noronha, and N. Shetty, Effect of Al2O3 and SiC nano-fillers on the mechanical properties of carbon fiber-reinforced epoxy hybrid composites. Journal of Composites Science, 7 (4), 133, 2023. https://doi.org/10.3390/jcs7040133.
• D. Bazrgari, F. Moztarzadeh, A. Sabbagh-Alvani, M. Rasoulianboroujeni, M. Tahriri, and L. Tayebi, Mechanical properties and tribological performance of epoxy/Al2O3 nanocomposite. Ceramics International, 44 (1), 1220-1224, 2018. https://doi.org/10.1016/j.ceramint.2017.10.068.
• A. Nabhan, M. Taha, and N. M. Ghazaly, Filler loading effect of Al2O3/TiO2 nanoparticles on physical and mechanical characteristics of dental base composite (PMMA). Polymer Testing, 117, 107848, 2023. https:// doi.org/10.1016/j.polymertesting.2022.107848.
• E. Çetkin, M. E. Demir, and R. K. Ergün, The effect of different fillers, loads, and sliding distance on adhesive wear in woven e-glass fabric composites. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 237 (2), 418-429, 2023. https://doi.org/10.1177/09544089221136808.
• C. Kanchanomai, N. Noraphaiphipaksa, and Y. Mutoh, Wear characteristic of epoxy resin filled with crushed-silica particles, Composites Part B: Engineering, 42 (6), 1446-1452, 2011. https://doi.org/10.1016/j.compositesb.2011.04.046.
• T. Raja, and Y. Devarajan, Investigation on boron carbide nanofiller-influenced epoxy polymer composite for thermal barrier applications. Biomass Conversion and Biorefinery, 14, 12623, 2023. https://doi.org/10.1007/s13399-023-04334-2.
• B. Ramesh, and B. Suresha, Optimization of tribological parameters in abrasive wear mode of carbon-epoxy hybrid composites. Materials & Design, 59, 38-49, 2014. https://doi.org/ 10.1016/j.matdes.2014.02.023.
• B. Suresha, B. Ramesh, K. Subbaya, B. R. Kumar, and G. Chandramohan, Influence of graphite filler on two-body abrasive wear behaviour of carbon fabric reinforced epoxy composites. Materials & Design, 31 (4), 1833-1841, 2010. https://doi.org/ 10.1016/j.matdes.2009.11.006.
• B. Suresha, S. Seetharamu, and P. S. Kumaran, Investigations on the influence of graphite filler on dry sliding wear and abrasive wear behaviour of carbon fabric reinforced epoxy composites. Wear, 267 (9-10), 1405-1414, 2009. https://doi.org/10.1016/j.wear.2009.01.026.
• A. Shalwan, and B. Yousif, Influence of date palm fibre and graphite filler on mechanical and wear characteristics of epoxy composites. Materials & Design, 59, 264-273, 2014. https://doi.org/ 10.1016/j.matdes.2014.02.066.
• M. Aslan, M. Tufan, and T. Küçükömeroğlu, Tribological and mechanical performance of sisal-filled waste carbon and glass fibre hybrid composites. Composites Part B: Engineering, 140, 241-249, 2018. https://doi.org/10.1016/j.compositesb.2017.12.039.
• G. M. Lin, G. Y. Xie, G. X. Sui, and R. Yang, Hybrid effect of nanoparticles with carbon fibers on the mechanical and wear properties of polymer composites. Composites Part B: Engineering, 43 (1), 44-49, 2012. https://doi.org/10.1016/j.compositesb.2011.04.029.
• E. Omrani, B. Barari, A. D. Moghadam, P. K. Rohatgi, and K. M. Pillai, Mechanical and tribological properties of self-lubricating bio-based carbon-fabric epoxy composites made using liquid composite molding. Tribology International, 92, 222-232, 2015. https:// doi.org/10.1016/j.triboint.2015.06.007.
• M. K Hossain, M. E Hossain, M. Hosur, and S. Jeelani, Flexural and compression response of woven E-glass/polyester–CNF nanophased composites. Composites Part A: Applied Science and Manufacturing, 42 (11), 1774-1782, 2011. https:// doi.org/10.1016/j.compositesa.2011.07.033.
• C. Gao, G. Guo, F. Zhao, T. Wang, B. Jim, B. Wetzel, G. Zhang, and Q. Wang, Tribological behaviors of epoxy composites under water lubrication conditions. Tribology international, 95, 333-341, 2016. https://doi.org/ 10.1016/j.triboint.2015.11.041.
• Y. Quan, W. Zhong, Investigation on drilling-grinding of CFRP. Frontiers of Mechanical Engineering in China, 4, 60-63, 2009. https://doi.org/10.1007/s11465-009-0008-y.
• S. Tamura, T. Matsumura, Delamination-free drilling of carbon fiber reinforced plastic with variable feed rate. Precision Engineering, 70, 70-76, 2021. https://doi.org/10.1016/j.precisioneng.2021.01.003
• X. Qiu, P. Li, C. Li, Q. Niu, A. Chen, P. Ouyang, T.J. Ko, Study on chisel edge drilling behavior and step drill structure on delamination in drilling CFRP. Composite Structures, 203, 404-413. 2018. https://doi.org/10.1016/j.compstruct.2018.07.007.
• A. Hrechuk, V. Bushlya, R. M’Saoubi, J.E. Ståhl, Experimental investigations into tool wear of drilling CFRP. Procedia Manufacturing, 25, 294-301. 2018. https://doi.org/10.1016/j.promfg.2018.06.086.
• L.M.P. Durão, D.J. Gonçalves, J.M.R. Tavares, V.H.C. de Albuquerque, A.A. Vieira, A.T. Marques, Drilling tool geometry evaluation for reinforced composite laminates. Composite structures, 92 (7), 1545-1550, 2010. https://doi.org/10.1016/j.compstruct.2009.10.035.
• I. Ozsoy, A. Demirkol, A. Mimaroglu, H. Unal, and Z. Demir, The influence of micro-and nano-filler content on the mechanical properties of epoxy composites. Strojniski Vestnik/Journal of Mechanical Engineering, 61 (10) ,601-609, 2015. https://doi.org/10.5545/sv-jme.2015.2632.
• B. R. Raju, B. Suresha, R. P. Swamy, and B. S. G. Kanthraju, Investigations on mechanical and tribological behaviour of particulate filled glass fabric reinforced epoxy composites. Journal of Minerals and Materials Characterization and Engineering, 1, 160-167, 2013. https://doi.org/10.4236/jmmce.2013.14027.
• A. Patnaik, and A. D. Bhatt, Mechanical and dry sliding wear characterization of epoxy–TiO2 particulate filled functionally graded composites materials using Taguchi design of experiment. Materials & Design, 32 (2), 615-627, 2011. https://doi.org/10.1016/j.matdes.2010.08.011.
• P. O. Hagstrand, F. Bonjour, and J. A. Månson, The influence of void content on the structural flexural performance of unidirectional glass fibre reinforced polypropylene composites. Composites Part A: Applied Science and Manufacturing, 36 (5), 705-714, 2005. https://doi.org/ 10.1016/j.compositesa.2004.03.007.
• B. Hulugappa, M. V. Achutha, and B. Suresha, Effect of fillers on mechanical properties and fracture toughness of glass fabric reinforced epoxy composites. Journal of Minerals and Materials Characterization and Engineering, 4 (1), 1-14, 2016. https://doi.org/10.4236/jmmce.2016.41001.
• Bhatia, S. Angra, and S. Khan, A review on mechanical and tribological characterization of boron carbide reinforced epoxy composite. Advanced Composite Materials, 30 (4), 307-337, 2021.https://doi.org/10.1080/09243046.2020.1759482.
• Rodrigues, and J. Broughton, Silane surface modification of boron carbide in epoxy composites. International Journal of Adhesion and Adhesives, 46, 62-73, 2013. https:// doi.org/10.1016/j.ijadhadh.2013.05.014.
• L. M. P. Durão, D. J. Gonçalves, J. M. R. Tavares, V. H. C. de Albuquerque, A. A. Vieira, and A. T. Marques, Drilling tool geometry evaluation for reinforced composite laminates. Composite structures, 92 (7), 1545-1550, 2010. https://doi.org/10.1016/j.compstruct.2009.10.035.
• Y. Quan, and W. Zhong, Investigation on drilling-grinding of CFRP. Frontiers of Mechanical Engineering in China, 4, 60-63, 2009. https://doi.org/10.1007/s11465-009-0008-y.
• S. Tamura, and T. Matsumura, Delamination-free drilling of carbon fiber reinforced plastic with variable feed rate. Precision Engineering, 70, 70-76, 2021. https://doi.org/10.1016/j.precisioneng.2021.01.003.
• X. Qiu, P. Li, C. Li, Q. Niu, A. Chen, P. Ouyang, T. J. Ko, Study on chisel edge drilling behavior and step drill structure on delamination in drilling CFRP. Composite Structures, 203, 404-413, 2018. https://10.1016/j.compstruct.2018.07.007.
• V. Krishnaraj, A. Prabukarthi, A. Ramanathan, N. Elanghovan, M. S. Kumar, R. Zitoune, and J. Davim, Optimization of machining parameters at high speed drilling of carbon fiber reinforced plastic (CFRP) laminates. Composites Part B: Engineering, 43 (4), 1791-1799, 2012. https://doi.org/10.1016/j.compositesb.2012.01.007.
• J. P. Davim, J. C. Rubio, and A. Abrao, A novel approach based on digital image analysis to evaluate the delamination factor after drilling composite laminates. Composites Science and Technology, 67 (9), 1939-1945, 2007. https://doi.org/10.1016/j.compscitech.2006.10.009.
• A. Abrao, P. Faria, J. C. Rubio, P. Reis, and J. P. Davim, Drilling of fiber reinforced plastics: A review. Journal of Materials Processing Technology, 186 (1-3), 1-7, 2007. https://doi.org/10.1016/j.jmatprotec.2006.11.146.
• X. Qiu, P. Li, Q. Niu, A. Chen, P. Ouyang, C. Li, and T. J. Ko, Influence of machining parameters and tool structure on cutting force and hole wall damage in drilling CFRP with stepped drills.The International Journal of Advanced Manufacturing Technology, 97, 857-865, 2018. https://doi.org/10.1007/s00170-018-1981-2.