TOOL WEAR PREDICTION IN DRILLING OF GFRP LAMINATES …that the Strength and modulus of the composites increases with decreasing temperature. Palanikumar et al. [ 26] studies on machining

TOOL WEAR PREDICTION IN DRILLING OF GFRP LAMINATES

USING NEURO FUZZY MODELLING

Dr.P.Sengottuvel1, Dr.J.Hameed Hussain 2

1,2 Professor, 1Department of Mechatronics, 2Department of Mechanical

Email Id - [email protected], [email protected],

BIST, BIHER, Bharath University, Chennai-73

Abstract

Recently the use of GFRP materials in engineering application has increased due to their

omni potential properties such as high strength to weight ratio and high specific stiffness. As

structural materials, fastening of GFRP structures cannot be avoided. The fastening efficiency

is largely dependent on the quality of machined holes. Due to the anisotropic and non-

homogenous structure of GFRP, there exist an extensive tool wear to the drill bit .The

excessive tool wear make the drilling process very expensive as only limited number of holes

can be drilled with one particular drill bit. High temperature, vibration and noise generated

during drilling were some of the factors responsible for tool wear during drilling various

GFRP laminates. Hence it is necessary to find out the optimized drilling condition which

minimizes the drill temperature, vibration and noise to minimize drill wear during drilling

GFRP laminates.

Mechanical properties of unidirectional laminates are very different from those random

laminates .Hence the study of directionality of the reinforcement has a significant effect

during drilling. The work presented here focuses on finding suitable drilling condition which

minimizes temperature, vibration and noise on GFRP laminates such as uni directional, bi

directional, woven and woven cross. Based on taguchi L16 Orthogonal Array, drilling

experiments were conducted on a CNC drilling machine for different type of GFRP

laminates. Input parameter used in the experiments for various drilling conditions were

spindle speed, feed and point angle.

A modelling algorithm, Adaptive Neuro Fuzzy Inference System (ANFIS) is used to find

flank wear in drilling process.

Keywords: Adaptive Neuro Fuzzy Inference System, Drill temperature, GFRP laminates,

Noise, Vibration.

International Journal of Pure and Applied MathematicsVolume 118 No. 18 2018, 747-766ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

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1 Introduction

GFRP’s are a very important engineering material. For composite matrix and reinforcement

systems, the reinforcement type and orientation will in most instances be the dominant

contributor to properties. Reinforcement forms for the various matrix systems are classified

as uni directional, bi directional, woven and woven cross.(1-8) In uni directional ,fiber

orientation in which all of the major fibres run in one direction whereas for bi-directional the

fiber run in two or more direction. Whereas woven fabrics are formed by interlacing two sets

of threads, the warp and the wept interlaced at right angles to create a single layer. The

fabrics integrity is maintained by the mechanical interlocking of fibers. woven reinforcement

are particularly useful for constructing shapes with double curvature since they can readily be

draped over quite complex formers, unlike uni directional prepegs which may wrinkle

because of their anisotropy. Woven cross fiber creates a little criss-cross pattern when all

those tiny fibers are actually woven together. (9-16)

Given the growing importance of GFRP’s in industry and manufacturing

much research has been conducted to understand the negative side effects of drilling GFRP’s

laminates. But this work has been done in a very fragmented manner, concentrating on

temperature, vibration and Noise during drilling process. Machining of laminate composite

depends on the direction of fiber and matrix and their effects on machining process.

Important requirement for thermoplastic matrices which are to be used in high performance

composite is thermal stability. Chemical decomposition brought on by elevated temperature

affect the mechanical and all other properties of the polymer matrix. Weinert et al. [1] studied

the effects of temperature on tool life during drilling FRPs in dry machining and wet

machining condition and found that tool temperature increases with increase in both cutting

speed and feed and tool wear is distinctively more in dry machining than in wet machining.(16-18)

According to Maninder Singh et al. [2] FRP composites have low thermal conductivity and

heat capacity. This affects the energy balance between the tool and workpiece ensuing in high

temperatures at the flank area of the drill bit. These thermal loads affect the machined

surface, cutting forces and tool life. (19-21)

Wilson et al. [3] have experimentally measured the temperature for uni directional and cross

ply laminates of carbon fiber reinforced plastic and analysed the properties in both

International Journal of Pure and Applied Mathematics Special Issue

748

longitudinal and transverse direction. The behaviour of glass fiber and polyester in

compression and also mechanical properties of CFRP uni directional laminates at low

temperature were studied by Dutia and schutz et al. [24,25] respectively. Both of them found

that the Strength and modulus of the composites increases with decreasing temperature.

Palanikumar et al. [26] studies on machining characteristics of glass fiber reinforced polymer

composites and found that increase in feed rate increased the heat generation and hence tool

wear, which resulted in the higher tool wear. The increase in feed rate also increase the

chatter and it produces incomplete machining at a faster traverse, which leads to more tool

wear and hence low feed rates are selected and is between 0.10 and 0.50 mm/rev.

According to Komanduri et al. [27] the high abrasiveness of GFRP fibres result in loss of

sharpness of cutting edges of the tool. This loss of sharpness affects the integrity of the holes

drilled, increases production costs, power consumption and the productivity of the drilling

tool. Blunt edges not only reduce the life of the tool but results in excessive chatter and poor

surface finishes including overheating of the tool and a requirement for more power and

thrust whilst drilling.

Amit Kumar Tanwer et al. [28] stated that in tensile as well as compression test unidirectional

oriented glass fiber composites have large value of all the properties such as Ultimate force,

yield force, compressive strength, tensile strength, elongation than bidirectional.

Vibration and Noise are found to be primarily dependent on fibre orientation and operating

conditions and tool geometry have less influence. Ramkumar et al. [29] stated that in

conventional drilling of GFRP, force fluctuation has been observed during drilling, since the

drill encounters two different materials, whereas in case of superimposed vibration, no such

severe fluctuation in force is observed. The severe force fluctuation observed in the case of

conventional drilling may be the cause for damage around the drilled holes. This damage

increases progressively with the increase in thrust force.

Ramulu et al. [30] stated that the cutting forces produced in the machining of fiber

reinforced plastic are influenced by the orientation of the fiber. The tool which generates the

smaller force is expected to be more effective in cutting. The measured vibration signal was

related to the drilling parameters and the state of the tool. It has been reported by lee that only

force and acceleration signals in the feed direction are significant, signals in the other


749

directions not revealing any useful information. Arul et al. [31] stated that, the defects in the

drilling of composites are due to thrust forces experienced by the work material. The

parametric influence on cutting force was experimentally evaluated.

Langella et al. [32] presented a mechanistic model for predicting thrust force and torque

when drilling composite materials which allows a focused approach to the description of the

most appropriate drill geometry and cutting parameters.

Rajpal singh et al. [33] predicted the effective thermal conductivity (ETC) using the volume

fraction and thermal conductivities of different fillers filled in polymer matrices.

Lim et al. [34] stated that vibratory system formed due to the effect of machining operation.

Vibrations are often unfavourable to the work piece, cutting tool and machine tool. Increase

in cutting forces often results in flank wear to the drill bit and work piece will be degraded.

Vikrant Gupta et al. [35] developed a modelling algorithm using ANFIS to predict the

effective thermal conductivity of different fibers in the polymer matrix.. Anastasios P et al.

[16] studied Adaptive neuro-fuzzy inference system in modelling fatigue life of

multidirectional composite laminates. Xu Lei et al. [36] used the dynamic mechanical

analysis and vibration test to reveal the dynamic behaviours of specimen. The effect of

woven structure was discussed and the resultant analysis was done.

It is eminent fact that high temperatures, vibration and noise formed during drilling laminates

are the cause of unsatisfactory cutting tool life. Therefore, the most suitable drilling

parameters have to be selected to minimize wear during drilling laminates. Studies about

various laminates are not discussed so far. So this study will be useful to find the influence of

temperature, vibration and noise on various laminates and to predict the optimized cutting

condition during drilling various laminates.

Drilling Temperature was measured with PFA Teflon-coated K type thermocouples with a

diameter of 115µm, vibration signal measured with accelerometer and noise measured with

microphone were the output parameter used for the investigation. Experiments were carried

out using 10mm diameter drill bit with various point angles 90° 120° 130° 140° to find out

the effect of flank wear of the drill bit on drilling various laminates.


750

The effect of tool wear on the various parameters has been analyzed by ANFIS. From the

observed results it was found that the predicted output tool wear is almost very close to the

actual output obtained in the experimental work. ANFIS model is validated with minimum

error, less than 5% which is experimentally reasonable. ANFIS improves the system accuracy

and eliminates the limitation in statistical modelling. This research would have served its

purpose if it aids in minimizing drill wear and damages caused to various GFRP’s laminates

whilst drilling.

2 Experimental setup

The drilling test were carried out on Hass CNCMILL USA model CNC milling

machine with maximum torque 104 Nm@12000 rpm, maximum power rating 20 HP.

Figure 1 represents the experimental setup.

Figure 1 CNC milling machine and measurement setup

2.1 Cutting tools

Four uncoated carbide drill bits with a diameter of 10mm were utilized in drilling

GFRP laminates. The dimensional properties of the drilling tool are as follows: tool overhang

47mm,point angle 90° 120° 130° 140°130˚ and Shank type is cylindrical. A total of 4

uncoated carbide drills were used and the performance of each drill bit was examined and

monitored for sixteen condition of various feed rate, spindle speed and point angle.


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2.2 Specimen preparation

In these experiments, the various GFRP laminates such are woven roving,

unidirectional, bidirectional and woven cross matrix specimen with dimensions 90 x 200 x 8

mm prepared through hand moulding technique and used as work piece. High strength E-

Glass Mat was used as reinforcement in epoxy resin with araldite as hardener and processed

to a room temperature for approx 3hrs to fabricate GFRP. The prepared laminates are an E-

glass/epoxy with a fiber volume fraction of 50%with a young’s modulus of 35Gpa and a

tensile strength of 60Mpa. The various laminates used in this study for investigation was

shown in figure 2.

Uni directional Bi directional Woven Woven cross

Figure 2 Different arrangement of GFRP orientation

2.3 Drilling test

An experiment was conducted on Hass CNC MILL USA Model computer numerical control

(CNC) milling machine (presented in figure 1) with a maximum torque of 104Nm at 1200

rpm,a maximum power rating of 20Hp,drill trials were conducted under four different cutting

conditions. The range of cutting condition for GFRP drilling was recommended by the ASM

machining data. They are listed in table 1. The orthogonal array selected was L16 (44). A

total of 16 experiments were carried out considering speed, feed, point angle and laminates


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for drilling. Each experiment has been repeated for four times and the temperature, vibration,

noise were recorded for each experiment.

Table 1 Four Levels of Testing the Experiment

2.4 Temperature Measurement

In this study, drill temperature was measured with PFA Teflon-coated K type thermocouples

with a diameter of 115 μm. The range of thermocouple is 0–500 °C, and its response time is

10 μs. OMB-PDQ 30 analog input expansion module with a sampling rate of 2MHZ is

connected with thermocouple output and interfaced with computer for investigation. The

thermocouple was fixed and positioned above the workpiece as shown in Figure 1.The

drilling temperature values are stored in laptop for further analyses.

2.5 Vibration measurement and Noise absorption

Vibration and noise during drilling the composite material were measured using Kistler

8636C50 piezo electric accelerometer and microphone. The accelerometer amplitude range

500g peak and frequency range 1 to 2000Hz and the microphone frequency range is

100~10000Hz, and minimum sensitivity to noise ratio 58dB. The data acquired from the

accelerometer mounted on the fixture are stored in laptop for further analyses using

DEWESOFT.

2.6 Flank wear measurement

Symbo

l

Factors Level 1 Level 2 Level 3 Level 4

F Feed(mm/min) 25 30 35 40

S Speed(rpm) 250 500 750 1000

θ Point angle(θ) 90 120 130 140

L laminates WC1 WOVEN2 BD3 UD4


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Maximizing the tool life by drilling through optimum drilling condition was the ultimate

objective of the present work. Flank wear was produced by the friction between the GFRP

laminates and the end flanks of the tool. This wear type was measured by using profile

projector.

3 Results and Discussion

The Experimental results of Temperature, Vibration and Noise of each sample are

shown in table 2.

Table 2 Temperature, Vibration and Noise absorption values for each Experiment

EX.

NO

SPINDLE

SPEED

(rpm)

FEED

RATE

(mm/

min)

POINT

ANGLE

(degree)

LAMINAT

ES

TEMPERA

TURE (ºc)

VIBRATI

ON

(g)

NOISE

(dBL)

TOOL

WEAR

(mm)

1 250 25 90 WC 62.956 29.101 88.78 0.0592

2 250 30 120 WOVEN 57.098 35.977 83.31 0.0540

3 250 35 130 BD 63.773 29.671 80.97 0.0330

4 250 40 140 UD 48.205 25.642 78.92 0.0526

5 500 25 120 BD 52.541 25.739 76.13 0.0281

6 500 30 90 UD 55.442 27.729 80.69 0.0329

7 500 35 140 WC 51.995 27.125 85.17 0.033

8 500 40 130 WOVEN 49.032 29.698 80.38 0.0369

9 750 25 130 UD 44.139 23.155 70.52 0.0154

10 750 30 140 BD 52.463 25.451 72.44 0.0183

11 750 35 90 WOVEN 47.609 28.219 76.58 0.0330

12 750 40 120 WC 61.682 28.99 87.77 0.0366

13 1000 25 140 WOVEN 46.789 23.955 71.79 0.0214

14 1000 30 130 WC 51.531 25.132 78.12 0.0230

15 1000 35 120 UD 46.76 24.517 76.52 0.0370

16 1000 40 90 BD 55.75 26.138 78.16 0.0369


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3.1 Experimental observation

The experimental results of temperature, vibration and noise obtained during drilling various

GFRP laminates at different cutting condition are shown in table 2.

From the experiment we found that the minimum temperature for unidirectional composite

was 44.139°C where as for bi directional, woven and woven cross the minimum temperature

obtained was 52.463°C, 46.789°C and 51.531°C respectively. In the same way minimum

vibration for unidirectional composite was 23.155g whereas for bi directional, woven and

woven cross minimum vibration was 25.451g, 23.955g 25.132g respectively. Similarly

minimum noise obtained during drilling uni directional GFRP laminates was 0.52dbl

whereas for bi directional, woven and woven cross the minimum noise obtained 72.44dbl,

71.79dbl and 78.12dbl. This shows that during drilling various laminates minimum

temperature, vibration and noise was obtained in uni directional laminates compared to other

laminates.

The influence of temperature on unidirectional composite was 79% whereas for bidirectional,

woven and woven cross was more than 80%.This shows the % influence of temperature was

less in unidirectional laminates compared to bidirectional, woven and woven cross. Similar

observation was found in vibration and noise.

The percentage of wear occurs in unidirectional composite is 29% whereas for bidirectional,

woven and woven cross was 49%, 39% and 33% respectively. This implies that wear

obtained during drilling unidirectional composite was less compared with other three

laminates (bidirectional, woven, woven cross).

Optimum cutting condition for minimizing Drill Temperature and vibration

The optimum cutting condition which minimizes the drill temperature and vibration

during drilling uni directional GFRP laminates is speed 750rpm, feed 25mm/min and

point angle 130°.

The optimum cutting condition for bi directional GFRP laminates is 750rpm, feed

30mm/min and point angle 140°.


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Woven GFRP laminates the optimum cutting condition is 1000rpm,feed 25mm/min

and point angle 140°

Spindle speed 1000rpm, feed 30mm/min and point angle 130° was the optimum

cutting condition for woven cross GFRP laminates.

Optimum cutting condition for minimizing noise

From the experiment we found that the optimum cutting condition which minimizes

the noise during drilling Uni directional GFRP laminates is spindle speed 250rpm,

feed 40mm/min and point angle 140°.

Similarly for bi directional GFRP laminates the optimum cutting condition was

spindle speed 250rpm, feed 35mm/min and point angle 130°.

The optimum cutting condition for woven GFRP laminates is spindle speed 250rpm,

feed 30mm/min and point angle 120°

For woven cross GFRP laminates the optimum cutting condition 250rpm, feed

25mm/min and point angle 90°.

3.2 Discussion

From above table 2 it was found that the minimum temperature, vibration and noise for

unidirectional composite was less when compared for woven, bidirectional and woven cross

This is due to the orientation of composite in one direction. Whereas for woven, bidirectional

and woven cross the orientations of fibers are in longitudinal and transverse direction. During

drilling this laminates, the interactions between the tool and fibers will be more. This

increases the temperature in woven, bidirectional and woven cross composites. The

temperature increase in woven cross is more when compared to woven due to the orientation

fibers at different angle.

Similarly it was found that vibration was more in woven, bidirectional and woven cross

composites compared to unidirectional composite .This is due to the twisting of the laminates

by the perpendicular arrangement of the warp and weft threads. From the literature we found

that the strength, stiffness &damping co-efficient of unidirectional composites was more

compared to other laminates. In general fibers in a one dimensional form are characterised by

flexibility, fineness and high ratio of length to thickness due to orientation of composite in


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one direction. Continuous fibers have long aspect ratio and normally have preferred

orientation.

4 ANFIS modelling on tool wear

Adaptive Neuro-fuzzy inference system is a fuzzy inference system implemented in the

framework of an adaptive neural network.

ANFIS is more powerful than the simple fuzzy logic algorithm and neural

networks. Since it provides a method for fuzzy modelling to learn information about the data

set, in order to compute the membership function parameters that best allow the associated

fuzzy inference system to track the given input/output data. The architecture of ANFIS for

flank wear is shown in Figure 3.

Figure 3 ANFIS Architecture

The seven inputs with one output and their final fuzzy membership functions are shown in

this figure 3. A total of 84 network nodes and 12 fuzzy rules were used to build the fuzzy

inference system.

A triangular – shaped membership functions were used to train ANFIS because it achieved

the lowest training error as shown in the training curve of Figure 4.Seven triangular-shaped

membership functions were used for inputs of spindle speed, feed rate, point angle, laminates,

temperature, vibration, noise. The input values are normalized by the mark signal and


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submitted for ANFIS training.

4.1 ANFIS training error curve

ANFIS predictions of tool wear starts by obtaining the data set (input-output data pairs) for

training. The data set is used to find the initial premise parameters for the fuzzy membership

functions by equally spacing each membership function. The values of the premise

parameters are fixed, so the overall predicted tool wear, can be expressed as a linear

combination of consequent parameters. Then, the output of ANFIS in Figure 4 shows the

predicted tool wear.

Figure 4 Trained output data for ANFIS

4.2 Validation of Neuro Fuzzy Model of Flank Wear

The wear testing on a new carbide drill bit with same specification is conducted. The flank

wear in every stages are noted. Then the obtained parameters are submitted for validation in

ANFIS as shown in table 3.Figure 5 shows the FIS model of ANFIS.

Each validation data point (spindle speed, feed rate, point angle, laminates,

temperature, vibration and noise) was fed into the system, and then the predicted tool wear

values were plotted with the actual experimental values of tool wear as shown in Figure 6.

This figure 6 shows that the predicted values are a close match to the actual ones.


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No of Inputs : 7 (Exclude Machining time)

FIS : Mandani Sub clustering

Algorithm : Hybrid

Total number of Input Membership Functions: 84 (7 inputs X 12 each)

Total number of Output Membership Functions: 12

Membership Function: Gaussian Membership Function

Figure 5 FIS MODEL

Figure 6 ANFIS Validation diagram


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Table 3 Validation of results

EX.N

O

SPINDLE

SPEED

(rpm)

FEED RATE

(mm/min)

POINT

ANGLE

(degree)

LAMINAT

ES

TEMPERAT

URE (ºc)

VIBRATION

(g)

NOISE

(dBL)

Tool

wear

(mm)

1 250 40 140 4 48.205 23.955 70.52 0.0214

2 500 25 120 3 52.463 25.739 76.13 0.0281

3 750 40 120 1 61.682 28.99 87.77 0.043

4 1000 40 90 3 63.773 29.671 80.97 0.0369

Actual values measured from the Profilometer and the output of FIS is shown in Table 3.

To validate the experimental values, tool wear values was measured for arbitrary cutting

condition and validated with ANFIS modelling. It was found from the figure 6 percentage of

error within 5% for tool wear. Since the % error was very less ANFIS was best suitable for

modelling the evaluation of tool wear. The instrument errors in measurement system and

uncertainty of machining parameters produce uneven rate of change in tool wear. This may

be the reason for the error, which is experimentally reasonable.

5 Conclusions

Tool abrasion reduces their work life considerably. Blunted tools results in excessive power

consumption, increase in production costs, excessive noise whilst drilling and a compromise

in the integrity of the composite materials. In the present work a comparison of tool wear

characteristics on drilling various laminates were studied. Drilling experiment was conducted

by changing the spindle speed (rpm), feed rate (mm/min) and point angle (degree). The


760

ANFIS model developed for the validation of flank wear model is carried out with 5% error

which is experimentally reasonable, because of its complex nomenclature.

Based on the experimental results the following conclusion can be drawn from drilling of

various GFRP laminates.

The spindle speed should be in the range of 62% from the rated speed in order to

obtained minimum wear during drilling various GFRP laminates.

The feed rate set should be in the range of 25-30mm/min and point angle must be in

the range of 130-140° to obtained less wear during drilling GFRP laminates.

The influence of temperature, vibration and noise in unidirectional composite was

very less compared to other laminates.

The percentage influence of temperature in unidirectional composite was 79%

whereas the percentage influence of vibration and noise was 86% and 87%

respectively. This shows the influence of vibration and noise was more in drill wear

when compared to temperature. Similar observation was found in bidirectional,

woven and woven cross.

The percentage of wear obtained during drilling unidirectional laminates was very

less compared to other laminates. This shows the significance of unidirectional

laminates over other laminates.

The investigation of drilling process has shown that unidirectional laminates was the

best suited laminates.

The statistical or analytical methods have certain limitations for non linear systems,

and for online application. The ANFIS solves the stated problems. The model

developed by neuro fuzzy system shows that the presented system can be used in real

time with minimum error.


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