Optimization of machining parameter in drilliing carbon fiber reinforced plastic (CFRP)

Kumaran, Lingges (2022) Optimization of machining parameter in drilliing carbon fiber reinforced plastic (CFRP). Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Composites are a substitute for metal components in airliner bodies and structures due to their light weight, which helps to reduce aircraft fuel consumption. One of them is, Carbon Fibre Reinforced Plastic (CFRP) which consists of several composite of material stacked in reinforced laminates component form, with varying material qualities throughout its structure. CFRP shows a wide range of drilling damage mechanisms because of its layered structure and anisotropy. During machining process, delamination is constantly linked to the thrust force that’s leads to a larger area of delamination at the entry and exit of the drill hole. This research aims to decrease the delamination area and thrust force by determining the optimal parameters for the drilling operation, including machine cutting speed, feed rate, and pecking depth. The thrust force during machining and delamination area at hole entry and exit are investigated by using variable spindle speed, feed rate and pecking depth from 1,500 to 3,000 rpm, 0.02 to 0.06 mm/rev and 2 to 4mm, respectively. The experiments were conducted systematically using a Full Factorial design. During this phase, the mathematical models for thrust force, entry delamination area, and exit delamination area were developed. Additionally, analysis of variance (ANOVA) was performed to determine the significance of the models. The error % of thrust force and delamination area at hole entry and exit is determined by three validation experiments. Based on the results, the error for delamination area and thrust force was less than 10%. At a feed rate of 0.02 mm/rev, a cutting speed of 1,500 rpm and pecking depth of 2.787 mm, the optimal conditions for minimal thrust force and delamination area were discovered.

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