Mechanistic approach for prediction of forces in micro-drilling of plain and glass-reinforced epoxy sheets

ORIGINAL ARTICLE
First Online:
Received:
Accepted:

Abstract

Aerospace and automobile industries extensively use components made of plastics and fiber-reinforced plastics which require micro-machining operations including micro-drilling to be carried out. Various attempts are reported in the literature to study different strategies and model the forces in micro-drilling with a view to produce micro-holes having large aspect ratio and to reduce drill breakage. The force models are more statistical than mechanistic in approach. In the present work, an attempt is made to develop mechanistic models of thrust and torque in micro-drilling of plain epoxy sheets. Material model capturing strain rate and temperature-dependent yield strength of epoxy material and basic principles of machining are employed for this purpose. The mechanistic model for prediction of thrust and torque is validated using well-planned full factorial design of experiments. Experiments are carried out using a carbide drill of 0.5-mm diameter with three levels for speed and feed on a high-speed miniature machine tool specially developed at the laboratory. The material model is extended to glass-reinforced plastics (GRP), and drilling forces are predicted using the proposed mechanistic model. In both cases of plain and GRP sheets, the model predictions are close to the experimentally measured drilling forces.

Keywords

Micro-drilling Epoxy Glass reinforced Mechanistic model Thrust force Torque 
This is a preview of subscription content, log in to check access.

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Chen WS, Ehmann KF (1994) An experimental investigation on the wear and performance of micro-drills. ASME Cent Res Tech Dev (CRTD) 30:145–157Google Scholar
  2. 2.
    Oxford CJ (1955) On the drilling of metals I: basic mechanics of the process. Trans ASME 77:103–114Google Scholar
  3. 3.
    Armarego E, Brown R (1969) The machining of metals. Prentice-Hall, Englewood CliffsGoogle Scholar
  4. 4.
    Wang J, Zhang Q (2008) A study of high-performance plane rake faced twist drills. Part II: predictive force models. Int J Mach Tools Manuf 48:1286–1295CrossRefGoogle Scholar
  5. 5.
    Rubenstein C (1991) The torque and thrust force in twist drilling—II. Comparison of experimental observations with deductions from theory. Int J Mach Tools Manuf 31:491–504CrossRefGoogle Scholar
  6. 6.
    Armarego E, Cheng C (1972) Drilling with flat rake face and conventional twist drills—I. Theoretical investigation. Int J Mach Tool Des Res 12:17–35CrossRefGoogle Scholar
  7. 7.
    Armarego E, Wright J (1984) Predictive models for drilling thrust and torques—a comparison of three flank configurations. Ann CIRP Manuf Technol 33:5–10CrossRefGoogle Scholar
  8. 8.
    Gong Y, Ehmann KF (2001) Mechanistic model for dynamic forces in micro-drilling, Proc 2001 ASME Int Mech Eng Cong Expo, New York, 1-10Google Scholar
  9. 9.
    Shaw MC (2003) The size effect in metal cutting. Sadhana 28:875–896CrossRefGoogle Scholar
  10. 10.
    Bissacco G, Hansen HN, Slunsky J (2008) Modelling the cutting edge radius size effect for force prediction in micro milling. Ann CIRP Manuf Technol 57:113–116CrossRefGoogle Scholar
  11. 11.
    Rao UM, Cumming JD, Thomsen EG (1964) Some observations on the mechanics of orthogonal cutting of Derlin and Zytel plastics. J Eng Ind 117–121Google Scholar
  12. 12.
    Kobayashi A (1967) Machining of plastics. McGraw-Hill, New YorkGoogle Scholar
  13. 13.
    Arola D, Ramulu M (1997) Orthogonal cutting of fibre-reinforced composites: a finite element analysis. Int J Mech Sci 39:597–613CrossRefMATHGoogle Scholar
  14. 14.
    Arola D, Sultan MB, Ramulu M (2002) Finite element modeling of edge trimming fibre-reinforced plastics. Trans ASME J Manuf Sci Eng 124:32–41CrossRefGoogle Scholar
  15. 15.
    Venu Gopala Rao G, Mahajan P, Bhatnagar N (2007) Micro-mechanical modeling of machining of FRP composites—cutting force analysis. Comp Sci Technol 67:579–593CrossRefGoogle Scholar
  16. 16.
    Khashaba UA (2004) Delamination in drilling GFR-thermoset composites. Comp Struct 63:313–327CrossRefGoogle Scholar
  17. 17.
    Khashaba UA (2013) Drilling of polymer matrix composites: a review. J Comp Mater 47(15):1817–1832CrossRefGoogle Scholar
  18. 18.
    Davim JP, Reis P, Antonio CC (2004) Experimental study of drilling glass fiber reinforced plastics (GFRP) manufactured by hand lay-up. Comp Sci Technol 64:289–297CrossRefGoogle Scholar
  19. 19.
    Singh I, Bhatnagar N, Viswanath P (2008) Drilling of uni-directional glass fiber reinforced plastics: experimental and finite element study. Mater Des 29:546–553CrossRefGoogle Scholar
  20. 20.
    Chandrasekharan V, Kapoor S, DeVor R (1995) A mechanistic approach to predicting the cutting forces in drilling: with application to fiber-reinforced composite materials. Trans ASME J Eng Ind 117:559–570CrossRefGoogle Scholar
  21. 21.
    Rahamathullah I, Shunmugam MS (2011) Thrust and torque analyses for different strategies adapted in micro-drilling of glass-fibre-reinforced plastics. Proc IMechE Part B: J Eng Manuf 225:505–519CrossRefGoogle Scholar
  22. 22.
    Rahamathullah I, Shunmugam MS (2013) Analyses of forces and hole quality in micro-drilling of carbon fabric laminate composites. J Comp Mater 47(9):1129–1140CrossRefGoogle Scholar
  23. 23.
    Rao S, Shunmugam MS (2012) Analytical modeling of micro end-milling forces with edge radius and material strengthening effects. Mach Sci Technol 16(2):205–227CrossRefGoogle Scholar
  24. 24.
    Río GT, Rodríguez J (2012) Compression yielding of epoxy: Strain rate and temperature effect. Mater Des 35:369–373CrossRefGoogle Scholar
  25. 25.
    Richeton J, Ahzi S, Daridon L, Rémond Y (2005) A formulation of the cooperative model for the yield stress of amorphous polymers for a wide range of strain rates and temperatures. Polymer 46:6035–6043CrossRefGoogle Scholar
  26. 26.
    Kaw AK (2006) Mechanics of composite materials (2nd Edition). CRC, FloridaGoogle Scholar
  27. 27.
    Han C-S, Nikolov S (2007) Indentation size effects in polymers and related rotation gradients. J Mater Res 22(6):1662–1672CrossRefGoogle Scholar
  28. 28.
    Wang S, Yang Y, Zhou LM, Mai Y-W (2012) Size effect in microcompression of epoxy micropillars. J Mater Sci 47(16):6047–6055CrossRefGoogle Scholar
  29. 29.
    Tounsi N, Vincenti J, Otho A, Elbestawi M (2002) From the basic mechanics of orthogonal metal cutting toward the identification of the constitutive equation. Int J Mach Tools Manuf 42:1373–1383CrossRefGoogle Scholar
  30. 30.
    Abdelmoneim ME, Scrutton RF (1974) Tool edge roundness and stable build-up formation in finish machining. Trans ASME 96:1258–1267Google Scholar
  31. 31.
    Kachanov LM (1971) Foundations of the theory of plasticity. North Holland, AmsterdamMATHGoogle Scholar
  32. 32.
    Mauch CA, Lauderbaugh LK (1990) Modeling the drilling process—an analytical model to predict thrust force and torque. Proc Comput Model Simul Manuf Process ASME PED 48:59–65Google Scholar
  33. 33.
    Srinivasa YV, Shunmugam MS (2009) Development and performance evaluation of miniaturized machine tool (MMT) system. Int J Nanomanufacturing 3(1/2):133–158CrossRefGoogle Scholar
  34. 34.
    Barbero EJ (2010) Introduction to composite materials design, 2nd edn. CRC, PhiladelphiaGoogle Scholar

Copyright information

© Springer-Verlag London 2014

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringGovernment College of EngineeringBargurIndia
  2. 2.Department of Mechanical EngineeringIndian Institute of Technology MadrasChennaiIndia

Personalised recommendations