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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Analysis of Surface Integrity of Aero Composite
Material in Drilling With High Speed Cutting
Tool
Thesis submitted in accordance with the requirements of the
Universiti Teknikal Malaysia Melaka for Degree of
Bachelor of Engineering (Honors) Manufacturing (Process)
By
Mohamad Anuar Bin Zainuddin
B050310175
Faculty of Manufacturing Engineering
November 2006
UTeM Library (Pind.1/2005)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap: Km 23,Jln Pengkalan Samak 2, Kg
Pengkalan Samak,77300 Merlimau,
Melaka.
Tarikh: _______________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
BORANG PENGESAHAN STATUS TESIS*
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
JUDUL: ANALYSIS OF SURFACE INTEGRITY OF AERO COMPOSITE MATERIAL IN DRILLING WITH HIGH SPEED CUTTING TOOL
SESI PENGAJIAN: 2/2006-2007 Saya _____________________________________________________________________ mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Kolej Universiti Teknikal Kebangsaan Malaysia (KUTKM) dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hak milik Kolej Universiti Teknikal Kebangsaan Malaysia. 2. Perpustakaan Kolej Universiti Teknikal Kebangsaan Malaysia dibenarkan
membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan (√)
MOHAMAD ANUAR BIN ZAINUDDIN
√
APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as partial
fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering
(Manufacturing Process). The members of the supervisory committee are as follow:
………………………………………….
Main Supervisor
(Mr Raja Izamshah Bin raja Abdullah )
13 April 2007
………………………………………….
Co-Supervisor
(Mr Edeerozey Bin Abd. Manaf )
13 April 2007
DECLARATION
I hereby, declare this thesis entitled
“Analysis of Surface Integrity of Aero Composite Material in Drilling With High speed
Steel Cutting Tool ”
is the results of my own research
except as cited in the reference.
Signature : ………………………………………….
Author Name : …………………………………………
Date : …………………………………………
MOHAMAD ANUAR BIN ZAINUDDIN
i
DEDICATION
Specially dedicated to my beloved parent, Zainuddin B. Haniff and Normah Bt.
Ahmad.
ii
ACKNOWLEDGMENTS
I like to thankful to Allah that was give me permission to complete and finish my
task in the degree thesis. Allah gives me life to do the job that was given to me. Next,
I want to regard my thankful to my parent that support me in material and soul to me.
With bless of them, I was complete my thesis and do the task.
The important person that was guides me in the thesis preparation and the project
preparation, Mr. Raja Izamshah B. Raja Abdullah. The person that gives me the
advice and the guidelines in the way to prepare the project and give some tips to
make sure the project can perform. Not forget to all lectures from Faculty of
Manufacturing that was give me the knowledge about the engineering field.
Lastly, I want send my thankful to all UTeM staff, my friend and all the people that
involved in my thesis and project. Thank you for all the help and support
iii
ABSTRACT
This thesis investigates the surface integrity of carbon fiber composite using high
speed steel drilling cutter. The experiments were carried out under dry cutting
conditions. The cutting speeds selected in the experiment in the range of 75 to
1050rpm. The drilling diameters used in the experiment were 4.0, 4.5, 5.0, 5.5 and
6.0mm. For a range of cutting speeds and drilling diameter, measurements of surface
roughness of machined surface and surface integrity were taken. From the
experimental result, the surface of carbon fiber composite is easily damaged during
machining operations due to the thrust force and torque occurs in drilling process.
Swelling, splitting and burrs were the most common defect that occurs during the
drilling process.
iv
LIST OF CONTENT
DEDICATION .............................................................................................................. i
ACKNOWLEDGMENTS ........................................................................................... ii
ABSTRACT ................................................................................................................ iii
LIST OF CONTENT .................................................................................................. iv
LIST OF FIGURE ..................................................................................................... vii
LIST OF TABLE ........................................................................................................ ix
CHAPTER 1 .................................................................................................................1
INTRODUCTION ....................................................................................................1
1.1 Introduction ...............................................................................................1
1.2 Objectives .................................................................................................2
1.3 Scope of Project .......................................................................................2
1.4 Problem Statements .................................................................................2
CHAPTER 2 .................................................................................................................4
LITERATURE REVIEW .........................................................................................4
2.1 Introduction ...............................................................................................4
2.2 Machining parameters ...............................................................................5
2.2.1 Cutting speed ....................................................................................5
2.2.2 Feed rate ............................................................................................6
2.2.3 Depth of cut ......................................................................................7
2.2.4 Spindle speed ....................................................................................7
2.3 Surface integrity ........................................................................................7
2.3.1 Technique for Testing Surface Structure ..........................................9
2.4 Roughness .................................................................................................9
2.3.1 Examples ...........................................................................................9
2.3.2 Theory .............................................................................................10
2.3.3 References .......................................................................................10
2.3.4 Surface metrology ...........................................................................10
2.3.5 Texture ...................................................................................................12
2.3.6 Roughness ..............................................................................................12
v
2.3.7 Waviness ................................................................................................12
2.3.8 Lay .........................................................................................................13
2.3.9 Flaws ...............................................................................................14
2.3.10 Profile ..............................................................................................14
2.3.11 Wavelength ..........................................................................................15
2.3.12 Waviness Profile ..................................................................................15
2.3.13 Least Squares Mean Line ................................................................16
2.3.14 Profile Peak .....................................................................................17
2.3.15 Profile ...................................................................................................18
2.4 Aero Composites ...........................................................................................19
2.4.1 Types ......................................................................................................21
2.4.2 Geometry ...............................................................................................21
2.4.3 Earliest Examples ..................................................................................22
2.4.4 Modern Composites ...............................................................................22
2.4.5 Mechanics ..............................................................................................22
2.4.6 Cermet ....................................................................................................24
2.5 Cutting Tools ................................................................................................25
CHAPTER 3 ...............................................................................................................30
METHODOLOGY .................................................................................................30
3.1 Selection of Machine ..............................................................................30
3.1.1 CNC Hass Machine ........................................................................30
3.2 Selection of Work Material .....................................................................31
3.3 Selection of Cutting Tool ........................................................................32
3.3 Parameters Setting ..................................................................................34
3.3.1 Cutting speed ..................................................................................34
3.5 Experiment ..............................................................................................34
3.6 Machining Test .......................................................................................36
3.6.1 Haas CNC Machine Safety .............................................................36
3.6.2 Setting Workpiece and Cutting Tools .............................................37
3.6.3 Transfer Program from Computer to CNC Machine/ Load
Program 37
3.6.4 Perform the CNC Operation ...........................................................38
vi
3.7 Surface Testing .......................................................................................38
3.7.1 Surface Roughness Tester Machine ................................................38
3.7.2 Scanning Electron Microscope Procedure (SEM) ..........................41
3.8 Programming ......................................................................................42
CHAPTER 4 ...............................................................................................................48
RESULTS AND DISCUSSION .............................................................................48
4.1 Failure at the Surface ....................................................................................48
4.2 Surface Roughness ........................................................................................50
CHAPTER 5 ...............................................................................................................56
SUMMARY AND CONCLUSIONS .....................................................................56
5.1 Summary and Conclusions ...........................................................................56
5.2 Recommendations .........................................................................................56
APPENDIX A .............................................................................................................57
APPENDIX B .............................................................................................................58
APPENDIX C .............................................................................................................59
APPENDIX D .............................................................................................................60
APPENDIX E .............................................................................................................61
APPENDIX F .............................................................................................................62
REFERENCE ..............................................................................................................63
vii
LIST OF FIGURE
Figure 1: Surface texture includes roughness and waviness. Many surfaces have lay
directional striations across the surface. .............................................................12
Figure 2: Several different types of lay are possible depending on the manufacturing
and machining processes. ...................................................................................13
Figure 3: A profile is a two-dimensional picture of a three dimensional surface that
may be thought of as the result of a sectioning place cutting the surface. Profiles
are ordinarily taken perpendicular to the lay. .....................................................14
Figure 4: Wavelength is the distance between similar points of a repeating, periodic
signal. ..................................................................................................................15
Figure 5: An important concept in surface finish is the breaking of a surface profile
into different components by wavelength. There is a hierarchy of components,
as shown. .............................................................................................................16
Figure 6: A least squares mean line minimizes the sum of the squares of the
deviations of a set of points from the line. This method approximates how your
eye would fit a line through a set of points .........................................................16
Figure 7: Profile peaks are regions above the mean line. Local peaks are regions
between two local minima. .................................................................................17
Figure 8: Profile Valleys extend below the mean line. Local valleys lie between two
maxima (above or below the mean line). ............................................................18
Figure 9: Mechanisms of delamination: (a) peel-up at entrance and (b) push-out at
exit [25] ...............................................................................................................28
Figure 10: CNC Haas Machine ...................................................................................30
Figure 11: Carbon graphite composite ........................................................................32
Figure 12: High speed steel drilling cutter ..................................................................33
Figure 13: Project flow chart ......................................................................................35
Figure 14: Mitotuyo surface tester machine ...............................................................39
Figure 15: Calibration process ....................................................................................40
Figure 16: The surface roughness tester preparation ..................................................40
Figure 17: Print out of the surface roughness value ...................................................41
viii
Figure 18: Scanning electron microscope ...................................................................42
Figure 19: Splinting defect at cutting speed 75rpm at drilling diameter (a) 4mm, (b)
4.5mm and (c) 5mm. ...........................................................................................50
Figure 20: Chart surface roughness vs. ø drill cutter for sampling length 0.25mm ...52
Figure 21: Chart surface roughness vs. ø drill cutter for sampling length 0.25mm ...52
Figure 22: Chart surface roughness vs. ø drill cutter for spindle speed 1050rpm ......53
Figure 23: Chart surface roughness vs. ø drill cutter for spindle speed 325rpm ........53
Figure 24: Chart surface roughness vs. ø drill cutter for spindle speed 75rpm ..........54
Figure 25: Picture when take the surface roughness using the surface roughness tester
SJ-301. (a) The specimen which wants to measure (b) Set up the specimen (c)
Start the measurement process (d) Print out the result. ......................................57
Figure 26: Surface roughness result printed ...............................................................58
Figure 27: Surface roughness result printed ...............................................................59
Figure 28: Surface roughness result printed ...............................................................60
Figure 29: Surface roughness result printed ...............................................................61
Figure 30: Surface roughness result printed ...............................................................62
ix
LIST OF TABLE
Table 1: A few solutions for overcoming the most common problems during drilling
process. [24] ........................................................................................................27
Table 2: Specifications of CNC Machine ...................................................................31
Table 3: Nominal composition of Carbon graphite composite. (Data from SEM). ....32
Table 4: General purpose for High Speed Steels (HSS) Cutting Tools. .....................33
Table 5: Table for cutting (rpm) speed vs diameter (mm) ..........................................34
Table 6: Morphology of drill hole for carbon graphite composite .............................49
Table 7: Surface roughness for sampling length 0.25mm x 1 ....................................51
Table 8: Surface roughness for sampling length 0.08mm x 1 ....................................51
Table 9: Sampling length for appendix profile roughness parameter (Ra, Rq, Rsk,
Rsu, RΔq) material ratio curve, probability density function, and related
parameter. (Evaluation according to JIS B0601-2001 and ISO) ........................55
1
CHAPTER 1
INTRODUCTION
1.1 Introduction
Drilling is one of the major machining operations which are currently carried out on
fiber-reinforced composite materials. There are typical problems encountered when
drilling fiber-reinforced composites. These problems include the delamination of the
composites, rapid tool wear, fiber pullout, presence of powdery chip, etc. The
delaminating of the composites is generally the main concern. This is so because the
occurrence of delamination wil1 reduce the strength against fatigue which result in a
poor assembly tolerance, and affect the composite’s structure integrity
Delamination usually occurs when the last plies of the material do not withstand to
force exacted by the drill bit’s chisel edge. Several authors studied their phenomena
and some avoid delaminating by means of controlling the thrust force at
breakthrough. Most of the researcher studied the effect of various parameter (cutting,
peed , feed, depth of cut and machining time) on drilling composite but none of the
research investigate the effect of tool diameter. This research will dealt with the
effect of cutting speed and cutter diameter on drilling composite.
2
1.2 Objectives
The objectives of this experiment are:
1. To study the effects of drilling parameters (cutting speed and drill diameter)
in drilling carbon graphite composite.
2. To analyzed the surface integrity of the material after the machining
operation.
1.3 Scope of Project
The scope of this project is to:
a) Perform the machining operation using drilling machine and high speed steel
cutting tool with carbon graphite composite.
b) To obtain the surface roughness value of the workpiece with different
parameter (cutting speed and cutter diameter).
c) To characterize type of defects occurs.
1.4 Problem Statements
The use of fiber-reinforced composite materials in automobile and aerospace
industries has grown considerably in recent years because of their unique properties
such as high specific stiffness and strength, high damping, good corrosive resistance,
and low thermal expansion. Drilling is usually the final operation during the
assembly of the structures in these applications.
Any defects that lead to the rejection of the parts represent an expensive loss. For
example, in the aircraft industry, drilling-associated delaminating accounts for 60%
of all part rejections during final assembly of an aircraft. The economic impact of
this is significant considering the value associated with the part when it reaches the
assembly stage. The quality of the drilled holes such as waviness/roughness of its
3
wall surface, axial straightness, and roundness of the hole cross-section can cause
high stresses on the rivet, which will lead to its failure. Stress concentration,
delamination, and microcracking associated with machined holes significantly reduce
the composites performance. Several hole production processes, including
conventional drilling, ultrasonic drilling, laser-beam drilling, water jet drilling, etc.,
have been proposed for a variety of economic and quality reasons. Conventional
drilling is still the most widely used technique in industry today. A major concern
that has received considerable attention in drilling holes in FRCM is the
delamination, especially at the bottom surface of the workpiece (drill exit). The
thrust force developed during the drilling process affects the width of the
delamination zone. This study is important in order to analyze the performance of
HSS twist drill with different speed and drill diameter in drilling with carbon
graphite composite.
4
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
Machining involves the shaping of apart through removal of material. A tool,
constructed of the material harder than the part being cut, is force against the part,
causing material to be cut from it. Machining, also referred to as cutting, metal
cutting or material removed, is the dominant manufacturing shaping process. It is
both a primary as well as a secondary shaping process. Machining is the term
generally used rather than material removal or cutting. The device that does the
cutting or material removal is known as cutting tool.
Drilling is one of the major machining operations which are currently carried out on
fiber-reinforced composite materials. There are typical problems encountered when
drilling fiber-reinforced composites. These problems include the delaminating of the
composites, rapid tool wear, fiber pullout, presence of powdery chip, etc. [1-3], and
the delaminating of the composites is generally the main concern. This is so because
the occurrence of delaminating will reduces the strength against fatigue, result in a
poor assembly tolerant, and affect the composite’s structure integrity [4,5]. Thrust
force has been widely cited as the main cause of delaminating. Ho-Cheng used a
fracture mechanics approach to analyze the delaminating of fiber-reinforced material
[6]. His analysis predicts the critical thrust force above which delaminating is
initiated. Tagliaferri and his co-researchers studied the effects of machining
parameters and tool conditions on the damage, finish and mechanica1 properties of
fiber-reinforced composite materials [7,8], and the cutting mechanism in drilling [9].
5
A close relationship between the thrust force and amount of damage was confirmed.
It was also found that the width of damage zone is correlated to the ratio between
drilling speed and feed rate. The higher ratio is the better the cut quality rate. Another
possible benefit of increasing cutting speed is the reduction of cutting forces. It has
already been found that the increase of cutting speed may decrease the cutting force
when cutting aluminum [10,l1] If the thrust forces can be reduced by increasing
cutting speed, the delaminating may be overcome. However, increasing cutting speed
wil1 accelerate tool wear, and the thrust force may increase as dril1 wear increases.
Therefore, it is of interest to study the effects of increasing drilling speed on thrust
forces as wel1 as other drilling characteristics. In this paper, the results of a series of
experimental tests are presented. The effects of increasing drilling speeds on thrust
force and torque are studied first. The effects of tool wear on dril1 geometries are
also examined. The effects of tool wear on cutting mechanism are then discussed.
Finally, conclusions are drawn based on these results.
2.2 Machining parameters
Machining parameters is the parameter that we will set on the machine before we
start the machining operation.
2.2.1 Cutting speed
Cutting speed is the work piece surface speed that crosses the cutting point. Cutting
speed usually count in meter per minutes. The calculation of cutting speed is create
from the length of the chips that was produce in the 1 minutes of cutting operation.
The parameter that influences the cutting speed is:
1. Types of the cutting tool
2. Depth of cut
3. Feed rate
4. Types of material
6
5. Types of cutting while roughing or finishing
6. Cutting fluids
The strength and hardness material usually used the low cutting speed and the
material that was soft using the high cutting speed. Beside that the work piece that is
small diameter also using the high cutting speed.
The different cutting speed for the different work piece to make sure the surface
that we get after machining was better surface and to ensure the tool life is longer.
Another factor that influence of the cutting speed is the spindle speed. The cutting
speed formula is such as show below.
V=DN
Where,
V = cutting speed
D = work piece diameter
N = spindle speed
2.2.2 Feed rate
Feed rate mean how many times of the cutting tool that touch the work piece during
the cutting operation. The tool was touch the rotational work piece and the unit of the
feed rate is mm per minutes (mm/min). The factors that influence the feed rate are:
1. Cutting speed
2. Strength of the work piece
3. Depth of cut
4. Types of cutting operation while roughing or finishing
5. Cutting fluids
7
The high feed rate is suitable for the roughing cut because this operation is not
necessary the better surface. For the finishing cut, the small feed rate is
recommending to get the better surface.
2.2.3 Depth of cut
Depth of cut is the thickness of the tool that was cut the work piece in the cutting
operation. The roughing operation need the high depth of cut compare the finishing
cut that need the small of depth of cut.
2.2.4 Spindle speed
Spindle speed is the speed of the machine rotation. In the turning operation, spindle
speed is the speed of the material movement. The spindle speed is measure in the
rotation per minute (rpm).
2.3 Surface integrity
Surface integrity describes not only the topological (geometric) features of surfaces
and their physical and chemical properties, but their mechanical and metallurgical
properties and characteristics as well. Surface integrity is an important consideration
in manufacturing operations because it influences properties, such as fatigue
strength, resistance to corrosion, and service life.
Surface Defect. Several defects caused by and produced during component
manufacturing can be responsible for inadequate surface integrity. These defects are
usually caused by a combination of factors, such as (a) defects in the original
material, caused by a casting or metalworking process, (b) the method by which the
surface is produced, and (c) lack of proper control of process parameters, which can
result in excessive stresses, excessive temperatures, or surface deformation [12].
8
The following are general definitions of the major surface defects (listed in
alphabetical order) found in practice:
1. Cracks are external or internal separations with sharp outlines;
cracks that require a magnification of 10X or higher to be seen by
the naked eye are called microcracks.
2. Craters are shallow depressions.
3. Folds are the same as seams.
4. Heat-affected zone is the portion of a metal which is subjected to
thermal cycling without melting.
5. Inclusions are small, nonmetallic elements or compounds in the
metal.
6. Intergranular attack is the weakening of grain boundaries through
liquid-metal embrittlement and corrosion.
7. Laps are the same as seams.
8. Metallurgical transformation involves microstructural changes
caused by temperature cycling (Chapter 4). These changes may
consist of phase transformations, re-crystallization, alloy depletion,
decarburization, and molten and recast, resolidified, or redeposited
material, as in electrical-discharge machining.
9. Pits are shallow surface depressions, usually the result of chemical
or physical attack.
10. Plastic deformation is a severe surface deformation cause by high
stresses due to friction, tool and die geometry, worn tools, and
processing method.
11. Residual stresses (tension or compression) on the surface are
caused by nonuniform deformation and nonuniform temperature
distribution.
12. Seams are surface defects which result from overlapping of the
material during processing.
13. Splatter is when small resolidified molten metal particles are
deposited on a surface, such as during welding.
9
2.3.1 Technique for Testing Surface Structure
One of the most commonly used techniques for testing surface integrity is
metallography. Sample from the workpiece are removed, polished, etched, and
observed under an optical or electron microscope. The test samples are usually much
smaller than the part of component being analyze, so it must be taken from
appropriate locations in the workpiece. As far asthe surface metallurgy of the
machined component is concerned, the heat generated during cutting is a main source
of damage, especially in the grinding process. Possible surface and subsurface
alterations include: plastic deformation, microcracking, phase transformations and
residual stress effects.
2.4 Roughness
Roughness or rugosity is a measurement (see surface metrology) of the small-scale
variations in the height of a physical surface. This is in contrast to large-scale
variations, which may be either part of the geometry of the surface or unwanted
'waviness'. Roughness is sometimes an undesirable property, as it causes friction,
wear, drag and fatigue, but it is sometimes beneficial, as it allows surfaces to trap
lubricants and prevents them from welding together. It is measured in different ways
for different purposes [14]. Here are some examples.
2.3.1 Examples
a. International Roughness Index (IRI) - a dimensionless quantity used for
measuring road roughness and proposed as a world standard by the World
Bank.
10
b. Average roughness (Ra). The average height of the bumps on a surface,
measured in micrometres or microinches.
c. Root mean square (RMS) roughness. Less common than average
roughness. Measured in the same units.
d. Roughness numbers, as defined by ISO 1302.
e. Manning's n-value - used by geologists to characterise river channels.
2.3.2 Theory
The mathematician Benoît Mandelbrot has pointed out the connection between
surface roughness and fractal dimension.
2.3.3 References
a) "Surface Finish Roughness Terminology" from Michigan Tech
b) "Surface Profile Parameters" at Surface Metrology Guide
c) "Surfaces and Profiles" (ibid.)
d) "International Roughness Index" at The University of Michigan
Transportation Research Institute (UMTRI)
e) "Propeller Roughness Definitions" at Phoenix Marine Services
f) "Verified Roughness Characteristics of Natural Channels" at USGS.
g) "A Theory of Roughness" - interview with Mandelbrot at edge.org
2.3.4 Surface metrology
Surface metrology is the science of measuring small-scale features on surfaces, and
is related to Metrology [15]. Surface roughness is the parameter most commonly
11
associated with the field. Surface metrology is important to many disciplines
including:
a) Tribology
b) Fluid Mechanics, especially Boundary layer theory.
c) Machining, Rolling and other Manufacturing
d) Optics
An instrument known as a profilometer often is used to measure a small-scale profile
of the surface. These traditionally used a stylus and worked much like a phonograph.
Newer versions often employ optical interferometry [16].
Parameters used to describe surfaces include:
a) Ra, Roughness Average (Absolute value of the surface height averaged over
the surface)
b) Rq, Root Mean Square (RMS) Roughness
c) Rv, Maximum Profile Valley Depth
d) Rp, Maximum Profile Peak Height
e) Rt, Maximum Height of the Profile (Rv+Rp)
f) Sm, Mean Peak Spacing
g) la, Average Wavelength
h) lq, RMS Average Wavelength
i) Da, Average Slope
j) Dq, RMS Average Slope
k) lr, Profile Length Ratio
l) Rsk, Skewness
m) Rku, Kurtosis
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