Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites
Carbon fibre-reinforced polymer (CFRP) composites have exceptional mechanical advantages such as high specific strength and stiffness, lightweight, and high damping capacity, making them very attractive for aircraft, aerospace, automotive, marine, and sporting applications. However, various defects...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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IOP Publishing
2024-01-01
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| Series: | Materials Research Express |
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| Online Access: | https://doi.org/10.1088/2053-1591/ad3522 |
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| author | S M Shahabaz Nagaraja Shetty Sathyashankara Sharma Jayashree P K S Divakara Shetty Nithesh Naik |
| author_facet | S M Shahabaz Nagaraja Shetty Sathyashankara Sharma Jayashree P K S Divakara Shetty Nithesh Naik |
| author_sort | S M Shahabaz |
| collection | DOAJ |
| description | Carbon fibre-reinforced polymer (CFRP) composites have exceptional mechanical advantages such as high specific strength and stiffness, lightweight, and high damping capacity, making them very attractive for aircraft, aerospace, automotive, marine, and sporting applications. However, various defects such as delamination, burr formation, and surface roughness are observed during the drilling of CFRP composites, which are influenced by various drilling process parameters. In this work, the drilling quality of uni-directional CFRP composites. and the hybrid Al _2 O _3 and hybrid SiC nano-composites are investigated experimentally using different types of drills such as step drill, core drill, and twist drill, as there is a limited study done on the comparative analysis of the impact of the above drills on the delamination factor and burr area on the above CFRP and hybrid nano-composites. The design of the experiment table was developed using response surface methodology (RSM) for input process parameters of spindle speed, feed, drill diameter, and drill type. The output surface characteristics (delamination factor and burr area) of the hole were measured quantitatively using the stereo zoom optical microscope. The main effect plots, contour plots, and analysis of variance (ANOVA) were used to examine the effect of spindle speed, feed, drill diameter, and drill type on exit delamination and burr formation. The analysis of main effect plots, contour plots, and analysis of variance showcased the optimum process parameters, such as a high spindle speed of 5500 rpm, low feed of 0.01 mm/rev, and drill diameter of 4 mm. The step drill demonstrated the least damage mechanism among drill geometries, followed by the twist and core drills. The minimum drilling damage was observed for the Al _2 O _3 hybrid nano-composite compared to the neat CFRP composites. |
| first_indexed | 2024-04-24T08:44:57Z |
| format | Article |
| id | doaj.art-09befe3c99bb4e26b60e7abb77f4a8d9 |
| institution | Directory Open Access Journal |
| issn | 2053-1591 |
| language | English |
| last_indexed | 2024-04-24T08:44:57Z |
| publishDate | 2024-01-01 |
| publisher | IOP Publishing |
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| series | Materials Research Express |
| spelling | doaj.art-09befe3c99bb4e26b60e7abb77f4a8d92024-04-16T13:39:03ZengIOP PublishingMaterials Research Express2053-15912024-01-0111303500610.1088/2053-1591/ad3522Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-compositesS M Shahabaz0Nagaraja Shetty1Sathyashankara Sharma2https://orcid.org/0000-0001-8995-1563Jayashree P K3S Divakara Shetty4Nithesh Naik5https://orcid.org/0000-0003-0356-7697Department of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education , Manipal 576104, Karnataka, IndiaDepartment of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education , Manipal 576104, Karnataka, IndiaDepartment of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education , Manipal 576104, Karnataka, IndiaDepartment of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education , Manipal 576104, Karnataka, IndiaAlva’s Institute of Engineering and Technology , Mijar, Moodabidri 574225, Mangalore, Karnataka, IndiaDepartment of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education , Manipal 576104, Karnataka, IndiaCarbon fibre-reinforced polymer (CFRP) composites have exceptional mechanical advantages such as high specific strength and stiffness, lightweight, and high damping capacity, making them very attractive for aircraft, aerospace, automotive, marine, and sporting applications. However, various defects such as delamination, burr formation, and surface roughness are observed during the drilling of CFRP composites, which are influenced by various drilling process parameters. In this work, the drilling quality of uni-directional CFRP composites. and the hybrid Al _2 O _3 and hybrid SiC nano-composites are investigated experimentally using different types of drills such as step drill, core drill, and twist drill, as there is a limited study done on the comparative analysis of the impact of the above drills on the delamination factor and burr area on the above CFRP and hybrid nano-composites. The design of the experiment table was developed using response surface methodology (RSM) for input process parameters of spindle speed, feed, drill diameter, and drill type. The output surface characteristics (delamination factor and burr area) of the hole were measured quantitatively using the stereo zoom optical microscope. The main effect plots, contour plots, and analysis of variance (ANOVA) were used to examine the effect of spindle speed, feed, drill diameter, and drill type on exit delamination and burr formation. The analysis of main effect plots, contour plots, and analysis of variance showcased the optimum process parameters, such as a high spindle speed of 5500 rpm, low feed of 0.01 mm/rev, and drill diameter of 4 mm. The step drill demonstrated the least damage mechanism among drill geometries, followed by the twist and core drills. The minimum drilling damage was observed for the Al _2 O _3 hybrid nano-composite compared to the neat CFRP composites.https://doi.org/10.1088/2053-1591/ad3522CFRPdrillingdelaminationburr formationresponse surface methodology |
| spellingShingle | S M Shahabaz Nagaraja Shetty Sathyashankara Sharma Jayashree P K S Divakara Shetty Nithesh Naik Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites Materials Research Express CFRP drilling delamination burr formation response surface methodology |
| title | Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites |
| title_full | Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites |
| title_fullStr | Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites |
| title_full_unstemmed | Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites |
| title_short | Optimization of drilling parameters on delamination and burr formation in drilling of neat CFRP and hybrid CFRP nano-composites |
| title_sort | optimization of drilling parameters on delamination and burr formation in drilling of neat cfrp and hybrid cfrp nano composites |
| topic | CFRP drilling delamination burr formation response surface methodology |
| url | https://doi.org/10.1088/2053-1591/ad3522 |
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