Machinability of multi-layer composite materials in milling machine process under dry machining

Abstract

Machinability allows a material to be cut economically and well. Good-machinability materials cut effortlessly and efficiently with low tool fatigue. Shear stress and particular power values make material machining and shaping harder, requiring larger pressures and slower velocities. Composites are made up of two parts. GFRP is well-known for its high strength-to-weight ratio, resistance to corrosion, and excellent electrical insulating qualities. Because of these qualities, GFRP is used in a wide range of industries, including construction, aerospace, automotive, and manufacturing. Machining these composites requires the right tools and cutting parameters. The objective of the study is to examine milling response parameters which is surface roughness and dimensional accuracy upon machined glass fiber-reinforced polymer in terms of composite materials in terms of linear and curvature cutting as well as drilling of glass fiber-reinforced polymer composite materials using a milling machine under dry cutting condition. There are 3 main parameters used to conduct this experiment which is cutting speed= 60m/min, feed per tooth = 0.03 mm and depth of cut = 2 mm. An 8 mm end mill coated tungsten carbide with TiAlN was used to perform to 27 samples with dimension 150 x 100 x 4 mm. Based on the research conducted, for surface roughness in straight line process, the data reveals that by increasing the cutting speed and feed per tooth resulting lower Ra value. For 1 mm depth of cut, the highest surface roughness is 0.8063 µm with 0.01 mm feed per tooth using 50 m/min of cutting speed while the lowest surface roughness was 0.4363 µm with 0.03 mm feed per tooth using 60 m/min of cutting speed. It was proved that the graph drastically decreases as the feed per tooth and cutting speed increase in 1,2 and 3 mm depth of cut. For dimensional accuracy, the graph trend shows that by increasing the feed per tooth and cutting speed resulting in the precise dimensional accuracy. For 2 mm depth of cut, the table shows that using 70 m/min of cutting speed with 0.02 mm feed per tooth, the accuracy is 8.0038 mm which is at the most precise compared to the other dimensional accuracy using 2 mm of depth of cut.