Abstract
Composite materials are preferred mostly in recent times due to their durability and ample space of applicability. Drilling is also an essential process in manufacturing, and it is frequently done to assemble products. Delamination due to drilling of the CFRP composite is considered as the primary concern in the manufacturing and assembly process. In this chapter, the empirical model for thrust force, torque, entry-delamination factor, exit-delamination factor, and eccentricity of drilling of CFRP composite is developed based on the extensive experiment. Response surface methodology is accounted to formulate a mathematical modal considering thrust force, torque, entry and exit-delamination factor, and eccentricity as response parameter and spindle speed, feed rate, and point angle as a process parameter. ANOVA is performed to check the statistical significance of the mathematical model. GA is employed to trace the optimum values of three process parameters to minimize the five response parameters. The Pareto front curve for various combinations of process parameters is also examined.
TopIntroduction
Composite materials are mostly used in the aerospace engineering and marine engineering field. In recent time composite material are widely used in many engineering fields due to its high strength to weight ratio, high tensile modulus to weight ratio, and high fatigue strength. Among the different types of composite material, fiber-reinforced composite materials are mostly applied to design aircraft components because of their high stiffness, low maintenance cost, lightweight, and it shows high internal damping. Due to advancements in manufacturing, the composite material can be designed as required. Among the manufacturing process, drilling is the most crucial process in mechanical assembly. Drilling in the fiber-reinforced composite material is challenging and also takes time and costly. Drilling in the fiber-reinforced composite leads to defects in a composite material such as delamination. Delamination can lead to failure of the component in use. Failure of an element due to drilling is depending on spindle speed, feed rate, and point angle. So, it is very obvious to trace the optimum drilling parameters to minimize the thrust force, torque, entry-delamination factor, exit-delamination factor, and eccentricity.
Key Terms in this Chapter
Delamination: Delamination is a type of defect in composite material. In loading condition, laminated composite materials split apart into layer that is called the delamination of a composite laminate.
Optimization: Optimization is a mathematical procedure to select the best decision variables from a set of alternatives to get the optimum objective value.
Drilling: Drilling is a cutting process that produces a circular hole in solid components by removing material from the surface.
Response Surface Methodology (RSM): RSM is a mathematical and statistical method that helps to build the regression model, which relates the input variables to output variables.
Carbon Fibre Reinforced Plastic (CFRP): CFRP is a type of composite material where carbon fibers are arranged in a polymer matrix. CFRP material has a high strength-to-weight ratio and stiffness.
Genetic Algorithm (GA): Genetic algorithm is a nature-inspired metaheuristic technique. GA mimic Charles Darwin’s theory of natural evolution.
Pareto Front: Pareto front gives the solution for multi-objective optimization. The Pareto front gives a set of optimal solutions that are non-dominating in nature.
Analysis of Variance (anova): ANOVA is a group of statistical models used to find the regression model or used to check the accuracy of the proposed regression model.