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Article

Jenarthanan Mugundhu, R. Jeyapaul and Naresh Neeli

The purpose of this paper is to develop a mathematical model for delamination through response surface methodology (RSM) and analyse the influences of the entire…

Abstract

Purpose

The purpose of this paper is to develop a mathematical model for delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, depth of cut and feed rate) on the responses in milling of glass fibre reinforced plastics (GFRP) composites with solid carbide end mill cutter coated with polycrystalline diamond (PCD).

Design/methodology/approach

Three factors, three levels face-centered central composite design matrix in RSM is employed to carry out the experimental investigation. Shop microscope is used to examine the delamination of GFRP composites. The “Design Expert 8.0” software was used for regression and graphical analysis of the data collected. Analysis of variance is used to check the validity of the model and for finding the significant parameters.

Findings

The developed second-order response surface model is used to calculate the delamination of the machined surfaces at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis of the influences of the entire individual input machining parameters on the delamination has been carried out using RSM.

Originality/value

Influence of solid carbide end mill coated with PCD on delamination of bi-directional GFRP composite during milling has not been analysed yet using RSM.

Details

Multidiscipline Modeling in Materials and Structures, vol. 9 no. 3
Type: Research Article
ISSN: 1573-6105

Keywords

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Article

M.P. Jenarthanan, A. Lakshman Prakash and R. Jeyapaul

This paper aims to develop a mathematical model for delamination during end milling by using response surface methodology (RSM) and to determine how the input parameters…

Abstract

Purpose

This paper aims to develop a mathematical model for delamination during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut and feed rate) influence the output response (delamination) in machining of hybrid glass fibre reinforced plastic (GFRP; abaca and glass) composite using solid carbide end mill cutter.

Design/methodology/approach

Three factors, three levels Box–Behnken design in RSM is used to carry out the experimental investigation. Shop microscope Mitutoyo TM-500 is used to measure the width of maximum damage of the machined hybrid GFRP composites. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter.

Findings

The RSM is used to predict the input factors influencing the delamination on the machined surfaces of hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination has been carried out using RSM.

Originality/value

Effect of milling of hybrid GFRP composite on delamination with solid carbide end mill has not been analysed yet using RSM.

Details

Pigment & Resin Technology, vol. 45 no. 5
Type: Research Article
ISSN: 0369-9420

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Article

M.P. Jenarthanan, A. Lakshman Prakash and R. Jeyapaul

The paper aims to develop a mathematical model for delamination and surface roughness during end milling by using response surface methodology (RSM) and to determine how…

Abstract

Purpose

The paper aims to develop a mathematical model for delamination and surface roughness during end milling by using response surface methodology (RSM) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre reinforced plastic (GFRP; Abaca and Glass) composite using solid carbide end mill cutter.

Design/methodology/approach

Four-factor, three-level Taguchi orthogonal array design in RSM is used to carry out the experimental investigation. The “Design Expert 8.0” is used to analyse the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter.

Findings

The feed rate is the cutting parameter which has greater influence on delamination (88.39 per cent), and cutting speed is the cutting parameter which has greater influence on surface roughness (53.42 per cent) for hybrid GFRP composite materials. Both surface roughness and delamination increase as feed rate increases, which means that the composite damage is larger for higher feed rates.

Originality/value

Effect of milling of hybrid GFRP composite on delamination and surface roughness with various helix angles of solid carbide end mill has not been analysed yet using RSM.

Details

Pigment & Resin Technology, vol. 45 no. 6
Type: Research Article
ISSN: 0369-9420

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Article

Rajkumar D, Ranjithkumar P, M.P. Jenarthanan and Sathiya Narayanan C

The purpose of this paper is to develop a statistical model for delamination and thrust forcing during drilling of carbon-fibre reinforced polymer (CFRP) composites using…

Abstract

Purpose

The purpose of this paper is to develop a statistical model for delamination and thrust forcing during drilling of carbon-fibre reinforced polymer (CFRP) composites using response surface methodology (RSM) to determine the input parameters (drill speed, drill diameter and feed rate) that influences the output response (delamination and thrust force) in the machining of CFRP composite using solid carbide drill cutter.

Design/methodology/approach

Three factors, three levels central composite face centred (CCFC) design, is used to conduct the experiments on CFRP by carbide drill. The whole quality evaluation (delamination) was done by video measuring system to measure the width of maximum damage of the machined CFRP composite. The thrust forces during drilling are measured using digital multi-component cutting force (Make: IEICOS, Model: 652) dynamometer. The “Design Expert 7.0” is used to analyse the data collected graphically. An analysis of variance is carried out to validate the model and for determining the most significant parameter.

Findings

The response surface model is used to predict the input factors influencing the delamination and thrust force on the drilled surfaces of CFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. The analysis on the influences of the entire individual input machining parameters on the delamination and thrust force has been carried out using RSM. This investigation revealed that the drill diameter is the eminent factor which affects the responses.

Originality/value

In all, 0.3, 0.4 and 0.5 mm holes have been successfully made on CFRP using vertical machining center, whereas the previous researchers have not drilled hole size less than 1 mm in CFRP using vertical machining center.

Details

Pigment & Resin Technology, vol. 46 no. 6
Type: Research Article
ISSN: 0369-9420

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Article

M.P. Jenarthanan, Karthikeyan M. and Naresh Neeli

The purpose of this paper is to develop a mathematical model for delamination during drilling by using a response surface methodology (RSM) and also to determine how the…

Abstract

Purpose

The purpose of this paper is to develop a mathematical model for delamination during drilling by using a response surface methodology (RSM) and also to determine how the input parameters (tool diameter, spindle speed and feed rate) influence the output response (delamination) in machining of fiber metal laminates.

Design/methodology/approach

Three factors and a three-level central composite design in RSM are used to carry out the experimental investigation. A video measuring system is used to measure the width of maximum damage of the machined FML composite. The “Design Expert 7.0” is used to analyze the data collected graphically. Analysis of variance is carried out to validate the model and for determining the most significant parameter.

Findings

The response surface model is used to predict the input factors influencing the delamination on the machined surfaces of the ARALL composite at different cutting conditions with the chosen range of 95 percent confidence intervals. Analysis of the influences of entire individual input machining parameters on the delamination has been carried out using RSM.

Originality/value

The effect of delamination on drilling of ARALL composites with solid carbide tools of various diameters has not been analyzed yet using RSM.

Details

Multidiscipline Modeling in Materials and Structures, vol. 13 no. 4
Type: Research Article
ISSN: 1573-6105

Keywords

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Article

M.P. Jenarthanan and R. Jeyapaul

The purpose of this paper is to develop a mathematical model for the surface delamination through response surface methodology (RSM) and analyse the influences of the…

Abstract

Purpose

The purpose of this paper is to develop a mathematical model for the surface delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, feed rate and depth of cut) on the responses in milling of carbon fibre reinforced polymer (CFRP) composites with solid carbide end mill cutter coated with polycrystalline diamond.

Design/methodology/approach

Three factors, three level face-centered central composite design in RSM was employed to carry out the experimental investigation. The “Design Expert 8.0” software was used for regression and graphical analysis of the data collected. The optimum values of the selected variables were obtained by solving the regression equation and by analyzing the response surface contour plots. Analysis of variance was used to check the validity of the model and for finding the significant parameters.

Findings

The developed second-order response surface model is used to calculate the delamination of the machined surfaces at different cutting conditions with the chosen range with 95 per cent confidence intervals. Using such model, one can obtain remarkable savings in time and cost.

Originality/value

The effect of machining parameters on surface delamination during milling of CFRP composites using RSM has not been previously analysed.

Details

Pigment & Resin Technology, vol. 43 no. 1
Type: Research Article
ISSN: 0369-9420

Keywords

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Article

M.P. Jenarthanan, Raahul Kumar S and Vinoth S

This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the…

Abstract

Purpose

This study aimed to develop a mathematical model for delamination and surface roughness during end milling by using grey relational analysis (GRA) and to determine how the input parameters (cutting speed, depth of cut, helix angle and feed rate) influence the output response (delamination and surface roughness) in machining of hybrid glass fibre-reinforced plastic (GFRP) (abaca and glass) composite using solid carbide end mill cutter.

Design/methodology/approach

The Four factors, three levels Taguchi orthogonal array design in GRA is used to conduct the experimental investigation. The Shop Vision inspection system is used to measure the width of maximum damage of the machined hybrid GFRP composite. The Shop Handysurf E-35A surface roughness tester is used to measure the surface roughness of the machined hybrid GFRP composite. “Minitab 14” is used to analyse the data collected graphically. Analysis of variance is conducted to validate the model in determining the most significant parameter.

Findings

The GRA is used to predict the input factors influencing the delamination and surface roughness on the machined surfaces of the hybrid GFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis on the influences of the entire individual input machining parameters on the delamination and surface roughness has been conducted using GRA.

Originality/value

Effect of milling of the hybrid GFRP composite on delamination and surface roughness with various helix angle solid carbide end mill has not been analysed yet using the GRA technique.

Details

Pigment & Resin Technology, vol. 46 no. 3
Type: Research Article
ISSN: 0369-9420

Keywords

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Article

M.P. Jenarthanan, R. Jeyapaul and N. Naresh

The purpose of this paper is to develop a mathematical model for surface roughness and delamination through response surface methodology (RSM) and analyse the influences…

Abstract

Purpose

The purpose of this paper is to develop a mathematical model for surface roughness and delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, fibre orientation angle, depth of cut and feed rate) on the responses in milling of glass fibre reinforced plastics (GFRP) composites with solid carbide end mill cutter coated with PCD.

Design/methodology/approach

Four factors, five level central composites and a rotatable design matrix in response surface methodology were employed to carry out the experimental investigation. “Design Expert 8.0” software was used for regression and graphical analysis of the data were collected. The optimum values of the selected variables were obtained by solving the regression equation and by analyzing the response surface contour plots. Analysis of variance (ANOVA) was applied to check the validity of the model and for finding the significant parameters.

Findings

The developed second order response surface model was used to calculate the surface roughness and delamination of the machined surfaces at different cutting conditions with the chosen range with 95 per cent confidence intervals. Using such a model, remarkable savings in time and cost can be obtained.

Originality/value

The effect of fibre orientation during milling of GFRP laminates using RSM has not been previously attempted for analysis.

Details

Multidiscipline Modeling in Materials and Structures, vol. 8 no. 4
Type: Research Article
ISSN: 1573-6105

Keywords

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Article

Gökhan Sur and Ömer Erkan

Drilling of carbon fiber reinforced plastic (CFRP) composite plates with high surface quality are of great importance for assembly operations. The article aims to optimize…

Abstract

Purpose

Drilling of carbon fiber reinforced plastic (CFRP) composite plates with high surface quality are of great importance for assembly operations. The article aims to optimize the drill geometry and cutting parameters to improve the surface quality of CFRP composite material. In this study, CFRP plates were drilled with uncoated carbide drill bits with standard and step geometry. Thus, the effects of standard and step drill bits on surface quality have been examined comparatively. In addition, optimum output parameters were determined by Taguchi, ANOVA and multiple decision-making methods.

Design/methodology/approach

Drill bit point angles were selected as 90°, 110° and 130°. In cutting parameters, three different cutting speeds (25, 50 and 75 m/min) and three different feeds (0.1, 0.15 and 0.2 mm/rev) were determined. L18 orthogonal sequence was used with Taguchi experimental design. Three important output parameters affecting the surface quality are determined as thrust force, surface roughness and delamination factor. For each output parameter, the effects of drill geometry and cutting parameters were evaluated. Input parameters affecting output parameters were analyzed using the ANOVA method. Output parameters were estimated by creating regression equations. Weights were determined using the analytic hierarchy process (AHP) method, and multiple output parameters were optimized using technique for order preference by Similarity to An ideal solution (TOPSIS).

Findings

It has been determined from the experimental results that step drills generate smaller thrust forces than standard drills. However, it has been determined that it creates greater surface roughness and delamination factor. From the Taguchi analysis, the optimum input parameters for Fz step tool geometry, 90° point angle, 75 m/min cutting speed and 0.1 mm/rev feed. For Fd, are standard tool geometry, 90° point angle, 25 m/min cutting speed and 0.1 mm/rev feed and for Ra, are standard tool geometry, 130° point angle, 25 m/min cutting speed and 0.1 mm/rev feed. ANOVA analysis determined that the most important parameter on Fd is the tip angle, with 56.33%. The most important parameter on Ra and Fz was found to be 40.53% and 77.06% tool geometry, respectively. As a result of the optimization with multiple criteria decision-making methods, the test order that gave the best surface quality was found as 4–1-9–5-8–17-2–13-6–16-18–15-11–10-3–12-14. The results of the test number 4, which gives the best surface quality, namely, the thrust force is 91.86 N, the surface roughness is 0.75 µm and the delamination factor is 1.043. As a result of experiment number 14, which gave the worst surface quality, the thrust force was 149.88 N, the surface roughness was 3.03 µm and the delamination factor was 1.163.

Practical implications

Surface quality is an essential parameter in the drilling of CFRP plates. Cutting tool geometry comes first among the parameters affecting this. Therefore, different cutting tool geometries are preferred. A comparison of these cutting tools is discussed in detail. On the other hand, thrust force, delamination factor and surface roughness, which are the output parameters that determine the surface quality, have been optimized using the TOPSIS and AHP method. In this way, this situation, which seems complicated, is presented in a plain and understandable form.

Originality/value

In the experiments, cutting tools with different geometries are included. Comparatively, its effects on surface quality were examined. The hole damage mechanism affecting the surface quality is discussed in detail. The results were optimized by evaluating Taguchi, ANOVA, TOPSIS and AHP methods together.

Details

Engineering Computations, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0264-4401

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Article

M.P. Jenarthanan, R. Gokulakrishnan, B. Jagannaath and P. Ganesh Raj

The purpose of this paper is to find out the optimum machining parameters using Taguchi technique with principal component analysis (PCA) during end milling of GFRP composites.

Abstract

Purpose

The purpose of this paper is to find out the optimum machining parameters using Taguchi technique with principal component analysis (PCA) during end milling of GFRP composites.

Design/methodology/approach

In multi-objective optimization, weight criteria of each objective are important for producing better and accurate solutions. This method has been employed for simultaneous minimization of surface roughness, cutting force and delamination factor. Experiments were planned using Taguchi’s orthogonal array with the machining parameters, namely, helix angle of the end mill cutter, spindle speed, feed rate and depth of cut were optimized with considerations of multiple response characteristics, including machining force, surface roughness and delamination as the responses. PCA is adopted to find the weight factors involved for all objectives. Finally analysis of variance concept is employed on multi-SN ratio to find out the relative significance of machining parameter in terms of their percentage contribution.

Findings

The multi-SN ratio is achieved by the product of weight factor and SN ratio to the performance characteristics in the utility concept. The results show that a combination of machining parameters for the optimized results has helix angle of 35°, machining speed of 4,000 m/min, feed rate of 750 mm/rev and depth of cut of 2.0 mm.

Originality/value

Effect of milling of GFRP composites on delamination factor, surface roughness and machining force with various helix angle solid carbide end mill has not been analysed yet using PCA techniques.

Details

Multidiscipline Modeling in Materials and Structures, vol. 13 no. 1
Type: Research Article
ISSN: 1573-6105

Keywords

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