Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology

In recent years, carbon fiber-reinforced polymer (CFRP) materials have gained tremendous attention from industries, especially in the aerospace industry due to their properties such as high strength-to-weight ratio and high corrosion resistance. In general, composite materials are usually manufactur...

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Main Author:	Sundi, Syahrul Azwan
Format:	Thesis
Language:	English English
Published:	2021
Subjects:	T Technology (General) TJ Mechanical engineering and machinery
Online Access:	http://eprints.utem.edu.my/id/eprint/25902/1/Machining%20Parameters%20And%20Tool%20Geometry%20Optimization%20For%20Trimming%20Composite%20Laminates%20Using%20Response%20Surface%20Methodology.pdf http://eprints.utem.edu.my/id/eprint/25902/2/Machining%20Parameters%20And%20Tool%20Geometry%20Optimization%20For%20Trimming%20Composite%20Laminates%20Using%20Response%20Surface%20Methodology.pdf
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id	my-utem-ep.25902
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Raja Abdullah, Raja Izamshah
topic	T Technology (General) TJ Mechanical engineering and machinery
spellingShingle	T Technology (General) TJ Mechanical engineering and machinery Sundi, Syahrul Azwan Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology
description	In recent years, carbon fiber-reinforced polymer (CFRP) materials have gained tremendous attention from industries, especially in the aerospace industry due to their properties such as high strength-to-weight ratio and high corrosion resistance. In general, composite materials are usually manufactured in a near-net shape. Hence, secondary processes such as trimming, drilling and countersinking are usually applied to obtain the final desired dimension. Composite behavior such as its inhomogeneity, anisotropy, and interaction with the cutting tool becomes challenging for the manufacturers. Matrix cracking, un-cut fibers, fibers pullout, and burned matrices are the typical problems or damages that arise during the machining process which may contribute to the rejection of parts. Moreover, the abrasive nature of the reinforcement fibers of the composite materials induces rapid wear rate to the cutting tool during machining which finally impacted the overall manufacturing cost. Therefore, this present study aims to determine an optimum tool geometry for a router tool-type (the number of teeth and the helix angles) and the optimized machining parameters in minimizing workpiece damages during the trimming of CFRP material. The trimming performances evaluated include the trimmed surface roughness in the longitudinal and transverse direction as well as the cutting force. Surface roughness evaluation was done by utilizing the portable surface roughness while cutting force was measured using the piezoelectric-dynamometer. Besides, further qualitative observation on the trimmed surface quality, and the effect on the tool wear, were performed using an optical microscope and a 3-Dimensional (3D) surface topography imager. The design of experiment (DOE-Taguchi and Response Surface Method-RSM) is the primary method deployed in the overall research’s milestones. Through the statistical analysis, the machining parameters (cutting speed, Vc, and feed per tooth, fz) resulted in a more significant effect on the surface roughness and the cutting force value than the selected tool geometry. On the other hand, considering only the tool geometry, the most predominant factor that affected the trimmed surface quality was the number of teeth on the left side, followed by the helix angle and the number of teeth on the right side. The relationship for each mentioned response, namely, the surface roughness (in the longitudinal and transverse direction) and the cutting force associated with the tool geometry, was successfully established using statistical model analysis. The optimum tool geometry (the combination of the number of teeth on the left and the right side respectively; 12, 8 and the helix angle; 24○) and the machining parameters (the cutting speed, Vc118.47 m/min and the feed per tooth, fz 0.05 mm/rev) were chosen based on the highest desirability score. The new optimum router tool geometry was fabricated and a validation experimental work was performed which finally confirmed its validity by obtaining the relative error between the predicted and the experimented data less than 10%. Ultimately, the main aim of the present study which was to determine an optimum tool geometry for a router tool-type geometry that can accommodate the trimming results, namely minimum surface roughness (the longitudinal and transverse direction), the cutting force and the tool wear has been successfully achieved.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Sundi, Syahrul Azwan
author_facet	Sundi, Syahrul Azwan
author_sort	Sundi, Syahrul Azwan
title	Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology
title_short	Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology
title_full	Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology
title_fullStr	Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology
title_full_unstemmed	Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology
title_sort	machining parameters and tool geometry optimization for trimming composite laminates using response surface methodology
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2021
url	http://eprints.utem.edu.my/id/eprint/25902/1/Machining%20Parameters%20And%20Tool%20Geometry%20Optimization%20For%20Trimming%20Composite%20Laminates%20Using%20Response%20Surface%20Methodology.pdf http://eprints.utem.edu.my/id/eprint/25902/2/Machining%20Parameters%20And%20Tool%20Geometry%20Optimization%20For%20Trimming%20Composite%20Laminates%20Using%20Response%20Surface%20Methodology.pdf
_version_	1747834145024770048
spelling	my-utem-ep.259022022-03-29T12:46:47Z Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology 2021 Sundi, Syahrul Azwan T Technology (General) TJ Mechanical engineering and machinery In recent years, carbon fiber-reinforced polymer (CFRP) materials have gained tremendous attention from industries, especially in the aerospace industry due to their properties such as high strength-to-weight ratio and high corrosion resistance. In general, composite materials are usually manufactured in a near-net shape. Hence, secondary processes such as trimming, drilling and countersinking are usually applied to obtain the final desired dimension. Composite behavior such as its inhomogeneity, anisotropy, and interaction with the cutting tool becomes challenging for the manufacturers. Matrix cracking, un-cut fibers, fibers pullout, and burned matrices are the typical problems or damages that arise during the machining process which may contribute to the rejection of parts. Moreover, the abrasive nature of the reinforcement fibers of the composite materials induces rapid wear rate to the cutting tool during machining which finally impacted the overall manufacturing cost. Therefore, this present study aims to determine an optimum tool geometry for a router tool-type (the number of teeth and the helix angles) and the optimized machining parameters in minimizing workpiece damages during the trimming of CFRP material. The trimming performances evaluated include the trimmed surface roughness in the longitudinal and transverse direction as well as the cutting force. Surface roughness evaluation was done by utilizing the portable surface roughness while cutting force was measured using the piezoelectric-dynamometer. Besides, further qualitative observation on the trimmed surface quality, and the effect on the tool wear, were performed using an optical microscope and a 3-Dimensional (3D) surface topography imager. The design of experiment (DOE-Taguchi and Response Surface Method-RSM) is the primary method deployed in the overall research’s milestones. Through the statistical analysis, the machining parameters (cutting speed, Vc, and feed per tooth, fz) resulted in a more significant effect on the surface roughness and the cutting force value than the selected tool geometry. On the other hand, considering only the tool geometry, the most predominant factor that affected the trimmed surface quality was the number of teeth on the left side, followed by the helix angle and the number of teeth on the right side. The relationship for each mentioned response, namely, the surface roughness (in the longitudinal and transverse direction) and the cutting force associated with the tool geometry, was successfully established using statistical model analysis. The optimum tool geometry (the combination of the number of teeth on the left and the right side respectively; 12, 8 and the helix angle; 24○) and the machining parameters (the cutting speed, Vc118.47 m/min and the feed per tooth, fz 0.05 mm/rev) were chosen based on the highest desirability score. The new optimum router tool geometry was fabricated and a validation experimental work was performed which finally confirmed its validity by obtaining the relative error between the predicted and the experimented data less than 10%. Ultimately, the main aim of the present study which was to determine an optimum tool geometry for a router tool-type geometry that can accommodate the trimming results, namely minimum surface roughness (the longitudinal and transverse direction), the cutting force and the tool wear has been successfully achieved. 2021 Thesis http://eprints.utem.edu.my/id/eprint/25902/ http://eprints.utem.edu.my/id/eprint/25902/1/Machining%20Parameters%20And%20Tool%20Geometry%20Optimization%20For%20Trimming%20Composite%20Laminates%20Using%20Response%20Surface%20Methodology.pdf text en public http://eprints.utem.edu.my/id/eprint/25902/2/Machining%20Parameters%20And%20Tool%20Geometry%20Optimization%20For%20Trimming%20Composite%20Laminates%20Using%20Response%20Surface%20Methodology.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=120067 phd doctoral Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Raja Abdullah, Raja Izamshah

Machining Parameters And Tool Geometry Optimization For Trimming Composite Laminates Using Response Surface Methodology

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