MAHENDRA ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT PHASE II

Modeling And Analysis Of Thrust Force And Torque In Drilling FRP

P.GOPINATH
REGNO:091007608004
UNDER THE GUIDENCE OF

Mr.R.PRABU M.E., SENIOR LECTURER/ MECH ENGG.,

Synopsis
Fiber reinforced polymers are finding increased applications in various engineering fields such as aerospace, automotive, electronics and other industries. Drilling is one of the most frequently practiced machining processes in industries In this project, experiments will be conducted using HSS drills. It brings about many undesirable results, such as rapid tool wear, rough surface finishes on finished components, and a defective sub-surface layer with cracks and de lamination. The results will indicate that the model can be effectively used for predicting the response variable by means of which can be controlled.

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Introduction
In order to drill holes efficiently with the least waste and defects, it is essential to understand the machining behavior of FRPs. Hence, the spindle speed, drill diameter, feed rate of the machining operation should be selected carefully

The effective joining is achieved by using proper drilled holes in the work piece material. In non homogeneity the joining is difficult.
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General Properties of FRP Composites

Hardness Specific gravity Thermal performance Chemical properties Electrical properties Fire resistance Optical properties

Literature Review
kevin schmit- project engineer identified One of the obstacles that
FRP (fiberglass reinforced plastic) sometimes has to overcome is proper design of the materials. FRP has unique properties that, if disregarded, can lead to failure during operation. However, when these same unique properties are taken advantage of, they can provide the user with a system superior to traditional metallic materials. This paper discusses some of the basic principles in designing process and facilities piping systems with FRP. Since many users are more familiar with traditional metallic materials, this papers presents those basic principles by comparing the performance of FRP to carbon steels, stainless steels, titanium, and copper-nickel [1] Carlo Pellegrino and Claudio Modena- studied the results of an experimental investigation on reinforced concrete (RC) rectangular beams strengthened in shear with externally bonded U-wrapped carbon fiber-reinforced polymer (CFRP) are presented and discussed. The results provide some new insights into the complex failure mechanisms that characterize the ultimate shear capacity of RC members with transverse steel reinforcement.[2]

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Arul, Vijayaraghavan Drilling trials have been carried out on glass

Fibre reinforced plastics (GFRP) with plain high speed steel (HSS), TiN coated HSS and tipped tungsten carbide drills. Most of the defects in drilling of composites are due to thrust force experienced by the workpiece. The parametric influence on cutting force was experimentally evaluated. The experimental results show that the defects toleranced drilling can be attained by proper selection of cutting parameters and tool material. This is substantiated by monitoring flank wear, hole shrinkage and acoustic emission during drilling. [3].

Aravindan & Naveen Sait identified Glass fiber reinforced plastics

(GFRP) play a vital role in many engineering applications as an alternative to various heavy exotic materials. In GFRP polymeric composites, the matrix of polymer (resin) is reinforced with glass fibers. Such composite pipes are finding applications not only in construction industries, but also in the transportation of corrosive fluid. These pipes are manufactured through hand lay-up or filament winding processes.[4]

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Vimal Sam Singh, LathaFiber

Studied reinforced polymer (FRP) composites have been steadily replacing metals as choice engineering materials for various applications. In order to drill holes efficiently with the least waste and defects, it is essential to understand the machining behavior of FRP. Drilling is one of the most frequently practiced machining processes in industries owing to the need for component assembly in mechanical structures.[5] Sedlek1,a and Humr Identified Delamination occurs along the fiber direction and develops in two phases: the chisel edge action phase and the cutting edge action phase. The first phase begins when the thrust force of the chisel edge into the exit surface reaches a critical value and ends when the chisel edge just penetrates the plate. By examining the photographs of exit surfaces and finished workpieces, it was found that the chisel edge has a strong effect on the formation of delamination. First a small bulge emerges in the vicinity of the drilling axis and then it develops along the fiber direction of the exit surface [6]

Problem Identification
Normally the structures are joined by drilling and riveting and or by using fasteners. The effective joining is achieved by using proper drilled holes in the work piece material. Due to the thrust developed during drilling, many common problems exist. Some of the problem causes in drilling are fiber breakage, matrix cracking, fiber/matrix debonding, fiber pull-out, fuzzing, thermal degradation, spalling and Delamination The thrust force and torque developed in drilling operation is an important concern. Monitoring of thrust force and torque in drilling is needed for the industry. Analyze the thrust force in drilling of composite materials, fuzzy logic rule based model is introduced in this work. Fuzzy logic is an important tool and it can be very useful for modeling the mechanical processes.

Methods
1. Experimental Method 2. Numerical Method 3. Fuzzy Logic

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1.Experimental setup
Parameters Spindle speed (rpm) Feed rate (mm/min) Drill diameter (mm) Torque (N-m) Thrust force (N) Levels 2 3 420 1750 80 120 10 12 1.75 435 2.86 505

1 210 40 8
0.62 249

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Drilling of FRP Material by DRO Drilling Machine

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Photo of Drilled FRP Material

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Photo of drilling M/C with dynamometer

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Experimental reading by using dynamometer

Hole no 01 02 03 04 05 06 07 Thrust force in kgf 38.02 49.13 64.32 54.43 64.42 76.45 68.70 Torque in kgf-m 0.122 0.14 0.165 0.178 0.202 0.262 0.243 Thrust force in N 373 482 631 534 632 750 674 Torque (N-m) 1.20 1.38 1.62 1.75 1.99 2.58 2.39

08
09

80.73
95.61

0.279
0.34

792
938

2.74
3.36

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2.Numerical method
It needs hardness of the material It has formulas for finding the value of thrust force and torque It doesnt bring accurate value as experimental value

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Formulas for Thrust and Torque

To find the torque
Mc = HBd2
_______

8 HB = Brinell Hardness

To find Thrust force

F = K x K x f x d __________ 2 K = GEOMETRY OF TIP K = SPECIFIC CUTTING FORCE f = FEED d = TOOL DIAMETER (mm)

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Analytical results for Thrust Force and Torque

Hole no Thrust force (N) Torque (N-m)

01
02 03 04 05 06 07 08 09

373.46
467.81 583.78 466.83 584.76 729.72 560.19 701.71 875.87

0.95
1.19 1.49 1.49 1.87 2.33 2.15 2.69 3.36

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3.Fuzzy Logic Method

It needs few experimental results It needs Fuzzy rule Fuzzy based model is developed to predict thrust force and torque in drilling of FRP composites

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Fuzzy rules
The fuzzy reasoning for three-input-two-output fuzzy logic unit is described as follows: The fuzzy rule base consists of a group of IF- THEN statements with three inputs, x1, x2 and x3 and an output y, i.e. Rule 1: if x1 is A1 and x2 is B1 and x3 is C1 then y1 is D1 and y2 is E1 else Rule 2: if x1 is A2 and x2 is B2 and x3 is C2 then y1 is D2 and y2 is E2 else Rule n: if x1 is An and x2 is Bn and x3 is Cn then y1 is Dn and y2 is En.
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Control parameters
Notations A B C Parameters Spindle speed (rpm) Feed rate (mm/min) Drill diameter (mm) Levels 1 2 3 210 420 1750 40 80 120 8 10 12

D E

Torque (N-m) Thrust force (N)

0.75 251

1.62 401

2.32 555

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Input parameters for Fuzzy Logic

Spindle Speed Feed rate Drill diameter

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Output parameters for Fuzzy Logic

Thrust force Torque

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Arrangement of number of Inputs and Outputs

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Input for Drill Diameter

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Input for Spindle Speed

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Input for Spindle Feed

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Rules for output

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Output for Thrust Force

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Output for Torque

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Results of Fuzzy Logic by using MATLAB

Hole no 01 02 03 04 05 06 07 08 09 Thrust force (N) 369.2 480 629.0 540 635.6 761.9 687.1 788 938 Torque (N-m) 1.09 1.26 1.56 1.69 2.03 2.53 2.46 2.84 3.26

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Comparision of Experimental , Fuzzy logic and Analytical results

Experimental result Hole No Thrust force (N) 01` 02 03 373 482 631 Torque (Nm) 1.20 1.38 1.62 Fuzzy Logic Result Thrust force (N) 369.2 480 629.0 1.09 1.26 1.56 Torque (N-m) (N) 373.46 467.81 583.78 m) 0.95 1.19 1.49 Analytical Result Thrust force Torque (N-

04
05 06 07 08 09

534
632 750 674 792 938

1.75
1.99 2.58 2.39 2.74 3.36

540
635.6 761.9 687.1 788 938

1.69
2.03 2.53 2.46 2.84 3.26

466.83
584.76 729.72 560.19 701.71 875.87

1.49
1.87 2.33 2.15 2.69 3.36

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Comparison between experimental and fuzzy

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Conclusion
1. The predicted output values and measured values are fairly close to each other, which indicate that the fuzzy logic model can be effectively used to predict the thrust force and torque in drilling FRP composites. 2. The verification results reveal that the fuzzy rule based model is suitable for predicting the thrust force and torque in drilling of composites. 3. Utilization of this system can improve the quality of drilled part; if online monitoring is introduced. This system can reduce the tedious model making, computational cost and time. 4. Further improvement of model can be possible by introducing more number of variables and wider range of cutting conditions

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REFERENCES
[1] Camposrubio, A.M. Abrao, P.E. Faria, A

Esteves Coreeia, and J. Paulo davim, Effects of high speed in drilling of

glass fibre reinforced plastic: evaluation of delamination factor, International Journal of Machine Tools & Manufacture, Vol.48, pp.715-721, 2008. [2] A.M.Abrao, P.E.Faria, J.C.Campos Rubio, and J.Paulo Davim, Drilling of fiber reinforced plastics: a review, Journal of Materials Processing Technology, Vol. 186, pp.1-7, 2007. [3] Luis Miguel Durao, Antonio G. Magalhaes, Joao Manuel R.S.Tavares, and A. Torres Marques, Analyzing objects in images for estimating the delamination influence on load carrying capacity of composite laminates, Electronic Letters on computer Vision and Image Analysis, Vol.7(2), pp.11-21, 2008. [4] C.Dandekar, E.Orady, and P.M.Mallick, Drilling characteristics of an eglass fabric reinforced polypropylene composite and an aluminum alloy: a comparative study, American Society of Mechanical Engineering, Vol.129, pp.14-18, 2007. [5] N.S.Mohan, S.M.Kulkarni, and A.Ramachandra, Delamination analysis in drilling process of glass fiber reinforced plastics (GFRP) composite materials, 34 Journal Plastics and Composites, DOI:

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THANKYOU

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