Investigating delamination, uncut fibers, tolerances and surface topography in high speed Drilling of Polypropylene Composite Reinforced with carbon fibers and calcium carbonate Nano-particles
Source abstract
Abstract
In this study, polypropylene composite reinforced with carbon fibers and calcium carbonate nano-particles is manufactured. Mechanical properties tests showed that composite sample containing nano-particles has 87% more tensile strength, 26% more bending strength and 40% more impact strength than the composite without nano-particles. Then high speed drilling was performed on the composite sample containing nano-particles. After drilling, the holes inlet opening surface was detected for uncut fibers and delamination defects. Dimensional tolerance of the holes inlet opening diameter, holes geometrical tolerances including circularity and cylindricity and also surface topography at the inner wall of the holes were investigated. The amount of uncut carbon fibers has direct relation with feedrate and reverse relation with spindle speed variations. With simultaneous increase of feedrate and spindle speed, uncut fibers are reduced. For each level of feedrate, with increasing spindle speed, the delamination defect decreases. The effect of spindle speed variations on the dimensional tolerance is far larger than the effect of feedrate changes. At low spindle speeds, the effect of feedrate changes on the geometrical tolerance variations is much higher. Optimal dimensional and geometrical tolerances are obtained in condition of the highest spindle speed and lowest feedrate. Although, increasing feedrate at very high levels of spindle speed leads to relative improvement in the drilling tolerances. Drilling with relatively lower feedrates and higher cutting speeds leads to better surface topography at the inner wall of the holes, consequently less surface defects such as cavity, debonding, matrix destroying, fiber pull-out and fiber dust are happened.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced machining processes and optimization · Advanced Machining and Optimization Techniques · Advanced Surface Polishing Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (28)
Show source-provided references
1. Rosato D V, Rosato D V (2005) Designs. Reinf. Plast. Handb, third edition. Elsevier, Chapter 7 https://doi.org/10.1016/B978-185617450-3/50009-810.1016/B978-185617450-3/50009-8 ↗
2. Koch CC, Ovid’ko IA, Seal S, Veprek S (2007) Structural nanocrystalline materials: fundamentals and applications. Cambridge University Press. https://doi.org/10.1017/CBO978051161884010.1017/CBO9780511618840 ↗
3. Kalpakjian S, Schmid SR (2001) Manufacturing engineering and technology. Pearson
4. Ashenai Ghasemi F, Hyvadi A, Payganeh G, Arab N (2011) Effects of drilling parameters on delamination of glass-epoxy composites. Aust J Basic Appl Sci 5:1433–1440
5. Kakinuma Y, Ishida T, Koike R, Klemme H, Aoyama T (2015) Ultrafast feed Drilling of Carbon Fiber-Reinforced Thermoplastics. Procedia CIRP 35:91–95. https://doi.org/10.1016/J.PROCIR.2015.08.07410.1016/J.PROCIR.2015.08.074 ↗
6. Durão L, Tavares J, de Albuquerque V, Marques J, Andrade O (2014) Drilling damage in composite material. Materials (Basel) 7(5):3802–3819. https://doi.org/10.3390/ma705380210.3390/ma7053802 ↗
7. Kazemi M, Jabbaripoor B, Imani BM, Sadeghi MH (2007) Investigating stability limits in high speed milling of titanium thin-walled parts," proceedings of 4th international conference on "design and production of machines and dies/molds. Cesme, Turkey, pp 175–181
8. Wang Z, Rahman M (2014) High-speed machining. Compr mater process 221–253. https://doi.org/10.1016/B978-0-08-096532-1.01113-410.1016/B978-0-08-096532-1.01113-4 ↗
9. Krishnaraj V, Zitoune R, Davim JP (2013) Drilling of Polymer-Matrix Composites. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-38345-810.1007/978-3-642-38345-8 ↗
10. Gowda BMU, Ravindra HV, Prakash GVN, Nishanth P, Ugrasen G (2015) Optimization of process parameters in drilling of epoxy Si3N4 composite material. Mater Today Proc 2(4-5):2852–2861. https://doi.org/10.1016/J.MATPR.2015.07.30010.1016/J.MATPR.2015.07.300 ↗
11. Feito N, Diaz-Álvarez J, López-Puente J, Miguelez MH (2016) Numerical analysis of the influence of tool wear and special cutting geometry when drilling woven CFRPs. Compos Struct 138:285–294. https://doi.org/10.1016/J.COMPSTRUCT.2015.11.06510.1016/J.COMPSTRUCT.2015.11.065 ↗
12. Karnik SR, Gaitonde VN, Rubio JC, Correia AE, Abrão AM, Davim JP (2008) Delamination analysis in high speed drilling of carbon fiber reinforced plastics (CFRP) using artificial neural network model. Mater Des 29(9):1768–1776. https://doi.org/10.1016/J.MATDES.2008.03.01410.1016/J.MATDES.2008.03.014 ↗
13. Gaitonde VN, Karnik SR, Rubio JC, Correia AE, Abrão AM, Davim JP (2008) Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites. J Mater Process Technol 203(1-3):431–438. https://doi.org/10.1016/j.jmatprotec.2007.10.05010.1016/j.jmatprotec.2007.10.050 ↗
14. Campos Rubio JC, da Silva LJ, de Leite WO, Panzera TH, SLMR F, Davim JP (2013) Investigations on the drilling process of unreinforced and reinforced polyamides using Taguchi method. Composite Part B: Eng 55:338–344. https://doi.org/10.1016/J.COMPOSITESB.2013.06.04210.1016/J.COMPOSITESB.2013.06.042 ↗
15. Krishnaraj V, Prabukarthi A, Ramanathan A, Elanghovan N, Senthil Kumar M, Zitoune R, Davim JP (2012) Optimization of machining parameters at high speed drilling of carbon fiber reinforced plastic (CFRP) laminates. Composite Part B: Eng 43(4):1791–1799. https://doi.org/10.1016/j.compositesb.2012.01.00710.1016/j.compositesb.2012.01.007 ↗
16. Rawat S, Attia H (2009) Wear mechanisms and tool life management of WC–co drills during dry high speed drilling of woven carbon fibre composites. Wear 267(5-8):1022–1030. https://doi.org/10.1016/J.WEAR.2009.01.03110.1016/J.WEAR.2009.01.031 ↗
17. Swolfs Y, Shi J, Meerten Y, Hine P, Ward I, Verpoest I, Gorbatikh L (2015) The importance of bonding in intralayer carbon fibre/self-reinforced polypropylene hybrid composites. Composite Part A Appl Sci Manuf 76:299–308. https://doi.org/10.1016/J.COMPOSITESA.2015.06.01710.1016/J.COMPOSITESA.2015.06.017 ↗
18. Gabr MH, Okumura W, Ueda H, Kuriyama W, Uzawa K, Kimpara I (2015) Mechanical and thermal properties of carbon fiber/polypropylene composite filled with nano-clay. Composite Part B: Eng 69:94–100. https://doi.org/10.1016/J.COMPOSITESB.2014.09.03310.1016/J.COMPOSITESB.2014.09.033 ↗
19. Ansari MJ, Jabbaripour B (2019) Manufacture and Comparsion of mechanical properties of reinforced polypropylene nanocomposite with carbon fibers and calcium carbonate nanoparticles. Iranian J Manuf Eng 6(5):1–12 (in Persian)
20. Davim J, Reis P (2003) Study of delamination in drilling carbon fiber reinforced plastics (CFRP) using design experiments. Compos Struct 59(4):481–487. https://doi.org/10.1016/S0263-8223(02)00257-X10.1016/S0263-8223(02)00257-X ↗
21. Shyha I, Soo SL, Aspinwall D, Bradley S (2010) Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites. J Mater Process Technol 210(8):1023–1034. https://doi.org/10.1016/J.JMATPROTEC.2010.02.01110.1016/J.JMATPROTEC.2010.02.011 ↗
22. Physical and mechanical specifications of carbon fiber n.d. http://www.g-angeloni.com/elenco-prodotti/reinforcements/fabrics/carbon/balanced/gg-200-p/ (accessed September 18, 2019)
23. Physical and mechanical specifications of Calcium Carbonate Nano-particles n.d. https://www.omya.com/Documents/SOG/Hakuenka_CCR.pdf (accessed September 18, 2019)
24. Physical and mechanical specifications of maleic anhydride compatibilizer n.d. https://plastics.ulprospector.com/datasheet/e243881/exxelor-po-1020 (accessed September 18, 2019)
25. Tarpani JR, Canto RB, Saracura RGM, Ibarra-Castanedo C, Maldague XPV (2014) Compression after impact and fatigue of reconsolidated Fiber-reinforced thermoplastic matrix solid composite laminate. Procedia Mater Sci 3:485–492. https://doi.org/10.1016/J.MSPRO.2014.06.08110.1016/J.MSPRO.2014.06.081 ↗
26. Basso I, Batista MF, Jasinevicius RG, Rubio JCC, Rodrigues AR (2019) Micro drilling of carbon fiber reinforced polymer. Compos Struct 228:111312. https://doi.org/10.1016/j.compstruct.2019.11131210.1016/j.compstruct.2019.111312 ↗
27. Li M, Huang M, Jiang X, Kuo CL, Yang X (2018) Study on burr occurrence and surface integrity during slot milling of multidirectional and plain woven CFRPs. Int J Adv Manuf Technol 97(1-4):163–173. https://doi.org/10.1007/s00170-018-1937-610.1007/s00170-018-1937-6 ↗
28. Li MJ, Soo SL, Aspinwall DK, Pearson D, Leahy W (2014) Influence of lay-up configuration and feed rate on surface integrity when drilling carbon fibre reinforced plastic (CFRP) composites. Procedia CIRP 13:399–404. https://doi.org/10.1016/j.procir.2014.04.06810.1016/j.procir.2014.04.068 ↗