VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANASANGAMA, BELAGAVI – 590018

A TECHNICAL SEMINAR

on
“MACHINING OF FIBRE REINFORCEMENT
POLYMER COMPOSITE”
Submitted by
MALLIKARJUNA DANAPLA
USN: 4JD16ME438

Under the Guidance of

Mr.Hemanth Raju.T M.Tech
Assistant Professor

JAIN INSTITUTE OF TECHNOLOGY

Department of Mechanical Engineering
DAVANAGERE 577006

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 CONTENTS
• Introduction
• Literature Review
• Machining of Fibre reinforcement polymer
composite
• Conclusion
• References

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 INTRODUCTION
• Advanced composite materials have been continuously engineered for
a wide spectrum of mechanical, physical and functional performance.
• Among many types of composite materials, fibre-reinforced polymer
(FRP) composites have been attractive and extensively used. As a
matter of fact, conventional metallic materials have been largely
substituted by FRP composites in many cases. For examples of FRP
composite applications include aerospace components, marine
components, racing car bodies, etc.
• In the fast growing manufacturing world, the main aim of the
manufacturer is to make good quality products at minimum cost and in
less time.
• The machining of the Composite materials is not easy when comparing
with traditional engineering materials because of their anisotropic
properties and inhomogeneous nature.

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 LITERATURE REVIEW
Authors Experimental Research Main Results
Equipment or Objectives
Methods
M.Ramesh et Surface Response Machining The average cutting
al. Methodology Characteristics of speed and low feed
fiber reinforced rate reduces the burr
polymer height during cutting.
composites.
B.V.Kavad et Conventional Drilling, Effects of Drilling VAD and UAD have
al. Vibration assisted on Glass Fiber lesser thrust hence
Drilling, (VAD) Reinforced Plastic. lesser delamination
Ultrasonic assisted compared to
Drilling (UAD). conventional drilling.
Hom Nath Drilling setup based Machinability of The minimum Surface
Dhakal et al. on Taguchi technique sustainable and roughness and
(HFRP and CFRP conventional fiber Delamination factor
composite samples) reinforced polymer of the two samples for
composites. the optimum drilling.
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 MACHINING OF FIBRE
REINFORCEMENT POLYMER
COMPOSITE
Drilling is essential operation in the assembly of the structural frames of automobiles and
aircrafts. The life of the joint can be critically affected by the quality of the drilled holes
There are basically two types of drilling processes under which all drilling techniques
and methods can be appropriately classified. These are:
• Conventional Drilling (CD), and
• Non-Convectional Drilling (NCD)

• Conventional Drilling of Fibre

Reinforcement Polymer (FRP) Composite
Conventional drilling refers to any material removal process for hole generation, which
involves the formation of chips from a work-piece by the direct contact of a wedge
shaped cutting tool which is harder than the work piece material, under machining
conditions.

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Problems Associated with FRP Composite Conventional
Drilling
1. Delamination Mechanisms
• Peel up at Entrance: This type of delamination effect is caused by the
tensile impact of the cutting thrust which pulls the laminate surface towards the
helical flutes of the drill bit at hole entrance.
• Push out at Exit: The push-out delamination is generated by the high thrust
force of the drill bit on the adjacent layers of the laminate.

Figure1. Combined Peel-up and Push-out Delamination in a Composite[3]

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2. Tool Wear (drill bit)
Conventional drilling of composite materials is usually accompanied by
relatively higher cutting thrust sufficient to damage the tool tip by flaking and
chipping mechanisms. Tool damage is usually characterized by excessive wear
and frictional heat; in cases of composites with hard and abrasive fibres and tool
edge dull by clogging; in cases of soft and sticky polymer matrix.

3. Surface Roughness and Dimensional inaccuracy

The importance of surface integrity, quality, dimensional and geometric
tolerances of holes when drilling Fibre Reinforcement polymer composites can
never be compromised. In addition formation of burrs and caps are another
causes of dimensional inaccuracy. They both reduced the fatigue life of the
assembly components. Burr occurred as a resultant effect of a plastic deformation
of a material under machining process (drilling).

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4. Fibre Pull-out, Fibre-Uncut
The high cutting thrust developed during their drilling operation destroys the
interfacial adhesion energy between the fibers and the matrix, resulting in
matrix de-bonding, and eventually fiber pull-out. Composite fiber pulled out
and parts of the fibers remained uncut (Figure 2), due to the drill wear caused
by an increased work piece- tool interface temperature and friction.

Figure 2: Fiber Pull-out, Fiber-Uncut Defects at hole Entry and Exit

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• Non-Conventional Drilling
 With regards to the sophisticated characteristics of the new age materials,
the conventional drilling techniques became relatively ineffective in
materials processing. More so, a great deal of restrictions associated with
the use of traditional drilling techniques for materials processing.
 The inability to satisfactorily drill complex shaped work piece materials;
particularly fibre reinforced composites.

Non-Conventional Drilling processes are classified based on the nature of their

energy domains, under which we have the mechanical, electrical, thermal and
chemical:
• Mechanical Energy: Water Jet Drilling (WJD), Abrasive Jet Drilling
(AJD), Ultrasonic Assisted Drilling (UAD).
• Electrical Energy: Electrical Discharge Drilling (EDD).
• Thermal Energy: Laser Beam Drilling (LBD), Plasma Arc Drilling
(PAD).
• Chemical Energy: Chemical and Electro-Chemical Drilling (ECD).

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• Ultrasonic Assisted Drilling (UAD) of FRP Composites.
This is a non-conventional drilling technique which utilizes high mechanical
vibration to produce drilling effects. It involves the high frequency vibration on a
drill bit at the feed direction.

Figure 3 : Ultrasonic Assisted Drilling

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• The drilling process in UAD is achieved by the high-frequency hammering
effect of the abrasive grains at the tool’s cutting edge on the surface of the
work piece.
• UAD being an advanced technology, has different mechanics of material
removal compared to CD. While material removal is continuous in CD,
UAD utilizes the impact of a low amplitude intermittence between the tool
and work piece interface to achieve high deformation rates.
• The results obtained from this technology over the years of discovery has
proven successful in applications where conventional drilling techniques
were ineffective.

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Drilling Parameters in UAD are:
Thrust Force and Torque: The thrust force developed in UAD has an optimal
value, and is significantly lower than that of CD techniques at all vibration
frequencies. Slight reduction in the thrust force during UAD at specific lower
cutting speeds. Similarly, the torque on the tool in UAD was comparatively
lower than that developed during CD techniques over the period of tool
engagement.
Cutting Speed: The cutting speed varied linearly with thrust force in UAD,
and was similar to that of CD. The thrust force reached its maximum value at
the lowest cutting speed. Consequently, it is recommended to employ high
cutting speeds during UAD.
Cutting Temperature: The temperature developed at the tool-work piece
interface during UAD is similar to that of CD, the cutting temperature increased
linearly with feed rate in CD, the high temperature in UAD remained constant
irrespective of the feed rate.

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• Advantages of UAD
 Ability to drill any type of materials, irrespective of their electrical
conductivity.
 Produces High Surface finish.
 Absence of thermal, electrical, and chemical effects.
 UAD can be used to machine hard materials like carbides, ceramics,
and industrial diamonds.
 Nearly zero torque is needed to operate the drill.

• Disadvantages of UAD
 UAD is an advanced technology, and so requires huge capital
investment to set-up.
 High Power consumption.
 Low Material Removal Rate.
 High rate of tool wear may result from chipping effects.
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 CONCLUSION
 There is a need for a better technique of drilling, UAD has been effectively
used for drilling of both brittle and ductile materials.
 UAD decreased drilling forces when drilling Fiber reinforcement polymer
composites, causing reduction in both delamination and surface roughness
defects respectively.
 The drilling force developed in UAD has been found lower than CD at all
vibration frequencies and has optimal quantity.
 Conclusively, non-conventional drilling technologies showed greater
effectiveness towards machining FRPs over their conventional drilling.

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 REFERENCES

1. B.V.Kavad, A.B.Pandey, M.V.Tadavi, H.C.Jakharia, A Review paper on

Effects on Glass fiber reinforced plastic composites, (2014)
2. M. Ramesh, A. Gopinath, C. Deepa, A Review Paperon Machining of
fiber reinforcement polymer composite composites.
3. Sikiru Oluwarotimi Ismail, Hom Nath Dhakal , Ivan Popov, Johnny
Beaugrand, Comprehensive study on machinability of sustainable and
conventional fibre reinforced polymer composites.
4. Meltem Altin Karatas, Hasan Gokkaya, A Review paper on machinability
of carbon fiber reinforced polymer and glass fiber reinforced polymer
composite materials.

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