Drilling Of Aero Composite Material

Farah Umaima, Miswan (2008) Drilling Of Aero Composite Material. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Composites are two or more material that is combined to form a much stronger structure than either material itself. Drilling process of aero composites material is the most critical procedure in the whole aspect of its manufacturing process. This study is focused on the analysis over the factor of feed rate and speed of the CNC milling machine for drilling through aero composite material. It is also to analyze the factor of drill bit type which Dagger drill bit, Fish Tail drill bit, and Twist drill bit have been chosen. This research is to investigate the interaction of factors values that are most suitable, the best type of drill bit and the application of backup plate to minimize or eliminate the defects on the aero composite panel during drilling process. The aero composite panel was cut into specimen size, 75 mm x 35 mm by using hacksaw to get 24 specimens. Then, a hole was drilled through each specimen with diameter of 5 mm with different orientation of feed rate and speed. The cutting speed and the feed rate for the drilling process is factorial arranged with high and low value. Half quantities of the specimen were drilled with backup plate laid under the specimen. Then, the side wall of the hole is measured by using Portable Surface Roughness Tester to measure the surface roughness. An observation to the condition of the drilled hole area is done with Scanning Electron Microscope (SEM) to compare the difference in backup plate application in machining and to see which drill bit produce best drilling job. Universal Testing Machine (UTM) was used to do flexural test and get the maximum force can be hold by the drilled panel. From the study, it was found that the interaction that produces higher maximum force that can be hold by drilled specimen is chosen to be the best interaction of factors can be use in drilling of aero composite material. The use of back up plate is also managed to reduce the burr and delamination of the panel. From the image analysis also we can see that the Twist drill is the best drill bit to be use.

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