Skip to main content
SpringerLink
Log in

Surface Roughness Assessment After Milling of Pure and Carbon Black Reinforced Polypropylene Materials

  • Conference paper
  • First Online:
Advances in Design, Simulation and Manufacturing VI (DSMIE 2023)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Included in the following conference series:

  • 387 Accesses

Abstract

Polypropylene (PP) material and its composites are preferred for many applications due to their advanced properties. Although PP material products are produced in a near-net shape, milling, which is a secondary machining process, is required to obtain dimensional tolerances, appropriate geometric shapes, and quality surfaces. For this reason, the chip removal process gains importance so that PP can be used in structural parts and assembled with different parts. In this study, milling of pure polypropylene (Pure PP) and carbon black reinforced polypropylene (CB-PP) composite investigated the effect of cutting speed (70, 100, and 130 m/min) and feed (0.4, 0.5, and 0.6 mm/rev) on the average surface roughness (Ra), chip morphology, and exit burr formation. In addition, the Ra value was predicted by mathematical modeling of the Ra. A relationship was established between the Ra and cutting parameters such as cutting speed, feed, and radial depth of cut. The experimental results showed that the Ra value decreased as the cutting speed increased and the exit burr area increased. Also, as the feed increased, the Ra value and the exit burr size increased. It was seen that the deviation of mathematical modeling from experimental results was 11% on average, and it was usable. It was observed that CB-PP gave better Ra than pure PP under the same cutting parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Log in via an institution
Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 169.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 219.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. Singer, R., Ollick, A.M., Elhadary, M.: Effect of cross-head speed and temperature on the mechanical properties of polypropylene and glass fiber reinforced polypropylene pipes. Alex. Eng. J. 60, 4947–4960 (2021). https://doi.org/10.1016/j.aej.2021.03.073

  2. Khan, M.J.H., Hussain, M.A.: Mujtaba, IM: Polypropylene production optimization in fluidized bed catalytic reactor (FBCR): Statistical modeling and pilot scale experimental validation. Materials 7, 2440–2458 (2014). https://doi.org/10.3390/ma7042440

  3. Rakesh, P.K., Singh, I. (eds.): MHFNN, Springer, Singapore (2019). https://doi.org/10.1007/978-981-13-6019-0

  4. Shagwira, H., Mbuya, T.O., Mwema, F.M., Herzog, M., Akinlabi, E.T.: Taguchi optimization of surface roughness and material removal rate in CNC milling of polypropylene + 5wt.% quarry dust composites. IOP Conf. Ser.: Mater. Sci. Eng. 1107, 012040 (2021). https://doi.org/10.1088/1757-899X/1107/1/012040

  5. Shukor, J.A., Said, S., Harun, R., Husin, S., Kadir, A.B.: Optimising of machining parameters of plastic material using Taguchi method. Adv. Mater. Process. Technol. 2(1), 50–56 (2016). https://doi.org/10.1080/2374068X.2016.1143216

  6. Bajpai, P.K., Singh, I.: Drilling behavior of sisal fiber-reinforced polypropylene composite laminates. J. Reinf. Plast. Compos. 32(20), 1569–1576 (2013). https://doi.org/10.1177/073168441349286

  7. Zhu, Z., Buck, D., Wang, J., Wu, Z., Xu, W., Guo, X.: Machinability of different wood-plastic composites during peripheral milling. Materials 15, 1303 (2022). https://doi.org/10.3390/ma15041303

  8. Shagwira, H., Mbuya, T.O., Akinlabi, E.T., Mwema, F.M., Tanya, B.: Optimization of material removal rate in the CNC milling of polypropylene + 60 wt% quarry dust composites using the Taguchi technique. Mater. Today: Proceed. 44, 1130–1132 (2021). https://doi.org/10.1016/j.matpr.2020.11.229

  9. Shagwira, H., Wambua, J., Mwema, F.M., Akinlabi E., Jen, T.C.: Investigation into the effects of milling input parameters on the material removal rate and surface roughness of polypropylene + 80 wt. % quarry dust composite during machining. Adv. Mater. Process. Technol. 8, 2410−2424 (2022). https://doi.org/10.1080/2374068X.2022.2045821

  10. Codolini, A., Li, Q.M., Wilkinson, A.: Influence of machining process on the mechanical behaviour of injection-moulded specimens of talc-filled Polypropylene. Polym. Testing 62, 342–347 (2017). https://doi.org/10.1016/j.polymertesting.2017.07.018

  11. Tran, D.S., et al.: Experimental investigation on machinability of polypropylene reinforced with miscanthus fibers and biochar. Materials 13, 1181 (2020). https://doi.org/10.3390/ma13051181

  12. Mudhukrishnan, M., Hariharan, Palanikumar, P.K.: Delamination analysis in drilling of carbon fiber reinforced polypropylene (CFR-PP) composite materials. Mater. Today: Proceed. 16, 792−799 (2019). https://doi.org/10.1016/j.matpr.2019.05.160

  13. Mudhukrishnan, M., Hariharan, Palanikumar, P.K., Latha, B.: Tool materials influence on surface roughness and oversize in machining glass fiber reinforced polypropylene (GFR-PP) composites. Mater. Manuf. Process. 32(9), 988−997 (2017). https://doi.org/10.1080/10426914.2016.1221098

  14. Yaşar, N., Günay, M., Kılık, E., Ünal, H.: Multiresponse optimization of drillability factors and mechanical properties of chitosan-reinforced polypropylene composite. J. Thermoplast. Compos. Mater. 35(10), 1660–1682 (2022). https://doi.org/10.1177/0892705720939163

  15. Kuram, E.: Micro-milling of unreinforced and reinforced polypropylene. Proc. IMechE Part B: J. Eng. Manuf. 233(1), 87–98 (2019). https://doi.org/10.1177/0954405417711737

  16. Savina, J.P., Raghavendra, B.V.: Effect of fabrication methods on mechanical properties and machining parameters of aluminium matrix composites-a review. Mater Today Proc. 5, 22576–22580 (2018). https://doi.org/10.1016/j.matpr.2018.06.631

  17. Porwal, H., et al.: Effect of lateral size of graphene nano-sheets on the mechanical properties and machinability of alumina nano-composites. Ceram Int. 42, 7533–7542 (2016). https://doi.org/10.1016/j.ceramint.2016.01.160

  18. Liao, Z., et al.: Influence of surface integrity induced by multiple machining processes upon the fatigue performance of a nickel based superalloy. J. Mater. Process. Technol. 298, 117313 (2021). https://doi.org/10.1016/j.jmatprotec.2021.117313

  19. Franco, P., Estrems, M., Faura, F.: Influence of radial and axial runouts on surface roughness in face milling with round insert cutting tools. Int. J. Mach. Tools Manuf. 44(15), 1555–1565 (2004). https://doi.org/10.1016/j.ijmachtools.2004.06.007

  20. Wojciechowski, S., Twardowski, P., Pelic, M., Maruda, R.W., Barrans, S., Krolczyk, G.M.: Precision surface characterization for finish cylindrical milling with dynamic tool displacements model. Precis. Eng. 46, 158–165 (2016). https://doi.org/10.1016/j.precisioneng.2016.04.010

  21. Wojciechowski, S., Twardowski, P., Wieczorowski, M.: Surface texture analysis after ball end milling with various surface inclination of hardened steel. Metrol. Meas. Syst. 21(1), 145–156 (2014). https://doi.org/10.2478/mms-2014-0014

  22. Pelayo, G.U., Olvera-Trejo, D., Luo, M., López de Lacalle, L.N., Elías-Zuñiga, A.: Surface roughness prediction with new barrel-shape mills considering runout: modelling and validation. Measurement 173, 108670 (2021). https://doi.org/10.1016/j.measurement.2020.108670

  23. Pavlenko, I., Ivanov, V., Gusak, O., Liaposhchenko, O., Sklabinskyi, V.: Parameter identification of technological equipment for ensuring the reliability of the vibration separation process. In: Knapcikova, L., Balog, M., Perakovic, D., Perisa, M. (eds.) 4th EAI International Conference on Management of Manufacturing Systems. EICC, pp. 261–272. Springer, Cham (2020). https://doi.org/10.1007/978-3-030-34272-2_24

  24. Sklabinskyi, V., Liaposhchenko, O., Pavlenko, I., Lytvynenko, O., Demianenko, M.: Modelling of liquid’s distribution and migration in the fibrous filter layer in the process of inertial-filtering separation. In: Ivanov, V., et al. (eds.) DSMIE 2018. LNME, pp. 489–497. Springer, Cham (2019). https://doi.org/10.1007/978-3-319-93587-4_51

  25. Dhokia, V.G., Kumar, S., Vichare, P., Newman, S.T.: An intelligent approach for the prediction of surface roughness in ball-end machining of polypropylene. Robot. Comput.-Integr. Manufact. 24(6), 835–842 (2008). https://doi.org/10.1016/j.rcim.2008.03.019

  26. Abhishek, K., Panda, B.N., Datta, S.: Mahapatra, SS: Comparing predictability of genetic programming and ANFIS on drilling performance modeling for GFRP composites. Proc. Mater. Sci. 6, 544–550 (2014). https://doi.org/10.1016/j.mspro.2014.07.069

  27. Dhokia, V.G., Kumar, S., Vichare, P., Newman, S.T., Allen, R.D.: Surface roughness prediction model for CNC machining of polypropylene. Proceed. Instit. Mech. Eng. Part B: J. Eng. Manufact. 222(2), 137–157 (2008). https://doi.org/10.1243/09544054JEM884

  28. Sagherian, R., Elbestawi, M.A.: A simulation system for improving machining accuracy in milling. Comput. Ind. 14, 293–305 (1990). https://doi.org/10.1016/0166-3615(90)90037-P

  29. Ozlu, B.: Investigation of the effect of cutting parameters on cutting force, surface roughness and chip shape in turning of Sleipner cold work tool steel. J. Faculty Eng. Archit. Gazi Univ. 36(3), 1241–1251 (2021). https://doi.org/10.17341/gazimmfd.668169

  30. Gaitonde, V.N., Karnik, S.R., Rubio, J.C., et al.: Surface roughness analysis in high-speed drilling of unreinforced and reinforced polyamides. J. Compos. Mater. 46, 2659–2673 (2012). https://doi.org/10.1177/0021998311431640

  31. Lishchenko, N.V., Larshin, V.P., Pitel, J.: Vibrational impact on milled surface irregularities. J. Eng. Sci. 7(1), A8–A16 (2020). https://doi.org/10.21272/jes.2020.7(1).a2

  32. Kuram, E.: Micro-machinability of injection molded polyamide 6 polymer and glass-fiber reinforced polyamide 6 composite. Compos. Part B: Eng. 88, 85–100 (2016). https://doi.org/10.1016/j.compositesb.2015.11.004

Download references

Acknowledgment

The research was partially supported by the Slovak Research and Development Agency (project SK-UA-21–0060) and the Ministry of Education, Science, Research and Sport of the Slovak Republic (projects VEGA 1/0080/20 and KEGA 028TUKE-4/2021). The results were partially obtained within the project “Intensification of production processes and development of intelligent product quality control systems in smart manufacturing” ordered by the Ministry of Education and Science of Ukraine (State Reg. No. 0122U200875).

Author information

Authors and Affiliations

  1. Yildiz Technical University, Besiktas, Istanbul, 34349, Turkey

    Ahmet Hakan Akin, Yusuf Furkan Yapan & Alper Uysal

  2. Lviv Polytechnic National University, 12, Stepana Bandery St., Lviv, 79013, Ukraine

    Yaroslav Kusyj

  3. Sumy State University, 2, Rymskogo-Korsakova St., Sumy, 40007, Ukraine

    Vitalii Ivanov

  4. Technical University of Košice, 1, Bayerova St., Prešov, 08001, Slovak Republic

    Vitalii Ivanov

Authors
  1. Ahmet Hakan Akin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yusuf Furkan Yapan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yaroslav Kusyj
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Vitalii Ivanov
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Alper Uysal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Alper Uysal .

Editor information

Editors and Affiliations

  1. Sumy State University, Sumy, Ukraine

    Vitalii Ivanov

  2. Poznań University of Technology, Poznań, Poland

    Justyna Trojanowska

  3. Sumy State University, Sumy, Ukraine

    Ivan Pavlenko

  4. Free University of Bozen-Bolzano, Bolzano, Italy

    Erwin Rauch

  5. Technical University of Košice, Prešov, Slovakia

    Ján Piteľ

Rights and permissions

Reprints and permissions

Copyright information

© 2023 The Author(s), under exclusive license to Springer Nature Switzerland AG

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Akin, A.H., Yapan, Y.F., Kusyj, Y., Ivanov, V., Uysal, A. (2023). Surface Roughness Assessment After Milling of Pure and Carbon Black Reinforced Polypropylene Materials. In: Ivanov, V., Trojanowska, J., Pavlenko, I., Rauch, E., Piteľ, J. (eds) Advances in Design, Simulation and Manufacturing VI. DSMIE 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-32767-4_24

Download citation

  • DOI: https://doi.org/10.1007/978-3-031-32767-4_24

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-031-32766-7

  • Online ISBN: 978-3-031-32767-4

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Search

Navigation