2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp)
| Format: | General Document |
|---|
| _version_ | 1860798027489345536 |
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| building | INTELEK Repository |
| collection | Online Access |
| collectionurl | https://intelek.unisza.edu.my/intelek/pages/search.php?search=!collection3 |
| copyright | Copyright©PWB2025 |
| country | Malaysia |
| date | 2017-04-10 |
| format | General Document |
| id | 15545 |
| institution | UniSZA |
| originalfilename | 15545_2b0f2b6a59de07a.pdf |
| person | Jailani Ismail |
| recordtype | oai_dc |
| resourceurl | https://intelek.unisza.edu.my/intelek/pages/view.php?ref=15545 |
| sourcemedia | Server storage Scanned document |
| spelling | 15545 https://intelek.unisza.edu.my/intelek/pages/view.php?ref=15545 https://intelek.unisza.edu.my/intelek/pages/search.php?search=!collection3 General Document Malaysia Library Staff (Top Management) Library Staff (Management) Library Staff (Support) Terengganu Faculty of Innovative Design & Technology English application/pdf 1.5 Server storage Scanned document Universiti Sultan Zainal Abidin UniSZA Private Access Universiti Sultan Zainal Abidin SAMBox 2.3.4; modified using iTextSharp™ 5.5.10 ©2000-2016 iText Group NV (AGPL-version) 2017-04-10 15545_2b0f2b6a59de07a.pdf 120 Down Milling Trimming process Manufacturing processes Plastic composites Machining 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) Copyright©PWB2025 Two different materials subjected to machining can behave differently when cutting them with the same tool, at the same cutting speed and feed rates, using the same machine, and working under similar conditions. Some may produce long curly chips (like mild steel); some may produce short chips (like cast iron); some may get a smooth finish; some may end up with a rough surface; some may produce chatter and some may produce lots of heat and quickly blunt the tool. The use of advanced materials which are commonly composed of carbon fibre, polimers and metal has increased due to their special mechanical and physical properties such as in the aeronautical, aerospace, automotive, biomechanical, mechanical and other industries. As a result of these properties and potential applications, there exists an urgent need to understand questions associated with the machinability of these materials. Obviously, for Carbon Fibre Reinforced Plastic with Aluminum grade 2024 (CFRP/Al2024) composites material, integrating into one single machining operation has proved to be more challenging due to the anisotropic and non-homogeneous structure of CFRP and ductile nature of Aluminum. This introduces several types of damages like matrix cracking and thermal alterations, fiber pullout and fuzzing during drilling and trimming which affect the quality of machined surface. Many of these problems occured due to inappropriate use of various cutting tool designs materials and cutting parameters. The research project aims to study and model machined surface quality of CFRP/Al2024 using Two Level Full Factorial Design experiment. This research project has three objectives. First, to perform the trimming process using down milling. Second, to statistically and graphically analyze the influence and interaction of cutting parameters. Third, to optimize cutting parameters in order to get the surface texture quality of CFRP/Al2024 to less than 1 µm. The trimming process was carried out via down milling on a stack of multidirectional CFRP/Al2024. Three cutting parameters were considered namely, spindle speed (N), feed rate (fr) and depth of cut (dc). Two level full factorial design was utilized to plan systematic experimental methodology. The analysis of variance (ANOVA) was used to analyze the influence and the interaction factors associated to surface quality. The results showed that the depth of cut is the most significant factor for Al2024, and for CFRP the spindle speed and feed rate are significant. The validation test showed average deviation of predicted to actual value surface roughness is 3.11% for CFRP and 3.43% for Al2024. Optimization of surface roughness for CFRP/Al2024 of below that 1 µm can be obtained at the setting of N = 11750 rpm, fr = 750 mm/min and = 0.255 mm respectively. Jailani Ismail Dissertations, Academic Thesis |
| spellingShingle | 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) |
| state | Terengganu |
| subject | Manufacturing processes Plastic composites Machining Dissertations, Academic |
| summary | Two different materials subjected to machining can behave differently when cutting them with the same tool, at the same cutting speed and feed rates, using the same machine, and working under similar conditions. Some may produce long curly chips (like mild steel); some may produce short chips (like cast iron); some may get a smooth finish; some may end up with a rough surface; some may produce chatter and some may produce lots of heat and quickly blunt the tool. The use of advanced materials which are commonly composed of carbon fibre, polimers and metal has increased due to their special mechanical and physical properties such as in the aeronautical, aerospace, automotive, biomechanical, mechanical and other industries. As a result of these properties and potential applications, there exists an urgent need to understand questions associated with the machinability of these materials. Obviously, for Carbon Fibre Reinforced Plastic with Aluminum grade 2024 (CFRP/Al2024) composites material, integrating into one single machining operation has proved to be more challenging due to the anisotropic and non-homogeneous structure of CFRP and ductile nature of Aluminum. This introduces several types of damages like matrix cracking and thermal alterations, fiber pullout and fuzzing during drilling and trimming which affect the quality of machined surface. Many of these problems occured due to inappropriate use of various cutting tool designs materials and cutting parameters. The research project aims to study and model machined surface quality of CFRP/Al2024 using Two Level Full Factorial Design experiment. This research project has three objectives. First, to perform the trimming process using down milling. Second, to statistically and graphically analyze the influence and interaction of cutting parameters. Third, to optimize cutting parameters in order to get the surface texture quality of CFRP/Al2024 to less than 1 µm. The trimming process was carried out via down milling on a stack of multidirectional CFRP/Al2024. Three cutting parameters were considered namely, spindle speed (N), feed rate (fr) and depth of cut (dc). Two level full factorial design was utilized to plan systematic experimental methodology. The analysis of variance (ANOVA) was used to analyze the influence and the interaction factors associated to surface quality. The results showed that the depth of cut is the most significant factor for Al2024, and for CFRP the spindle speed and feed rate are significant. The validation test showed average deviation of predicted to actual value surface roughness is 3.11% for CFRP and 3.43% for Al2024. Optimization of surface roughness for CFRP/Al2024 of below that 1 µm can be obtained at the setting of N = 11750 rpm, fr = 750 mm/min and = 0.255 mm respectively. |
| title | 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) |
| title_full | 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) |
| title_fullStr | 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) |
| title_full_unstemmed | 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) |
| title_short | 2016_Down Milling Trimming Process Optimization for Carbon Fibre Reinforced Plastic (Cfrp) |
| title_sort | 2016_down milling trimming process optimization for carbon fibre reinforced plastic (cfrp) |