Skip to main content
SpringerLink
Log in

Effect of machining parameters on surface quality and delamination of carbon/glass/epoxy hybrid composite material during end milling operation

  • Original Article
  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

Glass, carbon, and hybrid/glass/carbon-reinforced polymer composites are the most important materials used in defense, aerospace, automobile, and sports industry because of their excellent mechanical properties. End-milling process is the final and important machining process of composites to achieve the desired shape and dimensions. The main concern of this research is to minimize delamination and surface roughness in carbon/glass/epoxy hybrid composites after end milling. The effects of tool material, spindle speed, feed rate, and cut depth on delamination and surface quality were investigated. Taguchi design of experiment method was used to vary the machining parameters. Surface quality was examined by a surface roughness tester, and the delamination of milled surfaces was inspected by non-destructive technique using ultrasonic testing. The surface morphology of milled surfaces was studied by scanning electron microscopy. Results were verified by signal-to-noise ratio and analysis of variance technique. Carbon/glass/epoxy hybrid composite exhibited better surface finish with diamond flute end mill cutter, spindle speed of 1500 rpm, feed rate of 0.15 mm/min, and cut depth of 0.05 mm. After nondestructive testing, minimum delamination in carbon/glass/epoxy hybrid composite was found using diamond flute end mill cutter at a spindle speed of 1500 rpm, feed rate of 0.10 mm/min, and cut depth of 0.10 mm.

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

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. N. R. Mathivanan, B. S. Mahesh and H. A. Shetty, An experimental investigation on the process parameters influencing machining forces during milling of carbon and glass fiber laminates, Measurement, 91 (2016) 39–45.

    Article  Google Scholar 

  2. N. M. Cococcetta, D. Pearl, M. P. Jahan and J. Ma, Investigating surface finish, burr formation, and tool wear during machining of 3D printed carbon fiber reinforced polymer composite, Journal of Manufacturing Processes, 56 (2020) 1304–1316.

    Article  Google Scholar 

  3. H. Shi, S. Yuan, Z. Li, H. Song and J. Qian, Evaluation of surface roughness based on sampling array for rotary ultrasonic machining of carbon fiber reinforced polymer composites, Measurement, 138 (2019) 175–181.

    Article  Google Scholar 

  4. P. M. Gopal and K. S. Prakash, Minimization of cutting force, temperature and surface roughness through GRA, TOPSIS and Taguchi techniques in end milling of Mg hybrid MMC, Measurement, 116 (2018) 178–192.

    Article  Google Scholar 

  5. Y. He, J. Sheikh-Ahmad, S. Zhu and C. Zhao, Cutting force analysis considering edge effects in the milling of carbon fiber reinforced polymer composite, Journal of Materials Processing Technology, 279 (2020) 116541.

    Article  Google Scholar 

  6. A. A. A. Nasir, A. I. Azmi, T. C. Lih and M. S. A. Majid, Critical thrust force and critical feed rate in drilling flax fibre composites, Composites Part B: Engineering, 165 (2019) 222–232.

    Article  Google Scholar 

  7. M. S. Poor Dehghan and H. Heidary, Parametric study on drilling of GFRP composite pipe produced by filament winding process in different backup condition, Composite Structures, 234 (2020) 111661.

    Article  Google Scholar 

  8. Suresh Kannan I. and A. Ghosh, Anti-friction and wetting behavior of a new polymer composite coating towards aluminium and dry machining of AA2024 alloy by coated end mills, Journal of Materials Processing Technology, 252 (2018) 280–293.

    Article  Google Scholar 

  9. D. Ozkan, M. S. Gok, M. Oge and A. C. Karaoglanli, Milling behavior analysis of carbon fiber-reinforced polymer (CFRP) composites, Materials Today: Proceedings, 11 (2019) 526–533.

    Google Scholar 

  10. M. H. El-Hofy, S. L. Soo, D. K. Aspinwall, W. M. Sim, D. Pearson and P. Harden, Factors affecting workpiece surface integrity in slotting of CFRP, Procedia Engineering, 19 (2011) 94–99.

    Article  Google Scholar 

  11. J. P. Davim, P. Reis and C. C. António, A study on milling of glass fiber reinforced plastics manufactured by hand-lay up using statistical analysis (ANOVA), Composite Structures, 64 (2004) 493–500.

    Article  Google Scholar 

  12. H. Heidary, N. Z. Karimi and G. Minak, Investigation on delamination and flexural properties in drilling of carbon nanotube/polymer composites, Composite Structures, 201 (2018) 112–120.

    Article  Google Scholar 

  13. J. P. Davim and P. Reis, Damage and dimensional precision on milling carbon fiber-reinforced plastics using design experiments, Journal of Materials Processing Technology, 160 (2005) 160–167.

    Article  Google Scholar 

  14. N. F. H. A. Halim, H. Ascroft and S. Barnes, Analysis of tool wear, cutting force, surface roughness and machining temperature during finishing operation of ultrasonic assisted milling (UAM) of carbon fibre reinforced plastic (CFRP), Procedia Engineering, 184 (2017) 185–191.

    Article  Google Scholar 

  15. K. Saravanakumar, H. Subramanian, V. Arumugam and H. N. Dhakal, Influence of milled glass fillers on the impact and compression after impact behavior of glass/epoxy composite laminates, Polymer Testing, 75 (2019) 133–141.

    Article  Google Scholar 

  16. A. Levy and P. Hubert, Vacuum-bagged composite laminate forming processes: predicting thickness deviation in complex shapes, Composites Part A: Applied Science and Manufacturing, 126 (2019) 105568.

    Article  Google Scholar 

  17. G.-D. Wang, S. K. Melly, N. Li, T. Peng and Y. Li, Research on milling strategies to reduce delamination damage during machining of holes in CFRP/Ti stack, Composite Structures, 200 (2018) 679–688.

    Article  Google Scholar 

  18. I. S. N. V. R. Prashanth, D. V. Ravi Shankar, M. Manzoor Hussain and B. Chandra Mouli, Critical analysis in milling of gfrp composites by various end mill tools, Materials Today: Proceedings, 5 (2018) 14607–14617.

    Google Scholar 

Download references

Acknowledgements

This work was supported by the Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Science Education Korea (2018R1A6A1A03024509).

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, HITEC University, Taxila, Punjab, Pakistan

    Qaiser Saghir, S. Kamran Afaq & Tanveer Ahmed

  2. Department of Mechanical Engineering, COMSATS University Islamabad, Wah Campus, Wah Cantt, Pakistan

    Atta ur Rehman Shah

  3. Department of Mechanical Engineering, Changwon National University, Changwon, Korea

    Jung-il Song

Authors
  1. Qaiser Saghir
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Atta ur Rehman Shah
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. S. Kamran Afaq
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Tanveer Ahmed
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jung-il Song
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Atta ur Rehman Shah or Jung-il Song.

Additional information

Qaiser Saghir has completed his Master of Science in Mechanical Engineering from HITEC University Taxila, Pakistan. His major during Master was Design and Manufacturing. His research focus is on machining of polymer composites material to minimize delamination and improve surface quality of machining surfaces.

Atta ur Rehman Shah is an Associate Professor and Chairman at the Department of Mechanical Engineering in COMSATS University Islamabad (Wah Campus), Pakistan. He has received his Ph.D. in Mechanical Engineering from Changwon National University, South Korea in 2016. His research interests include preparation, characterization, machining and weather aging of biobased and synthetic nanocomposites and hybrid composites.

S. Kamran Afaq is a Professor and Vice Chancellor in HITEC University Taxila, Pakistan. He has received his Ph.D. from University Paol Sabatier, Toulouse III, France. His research interest lies in design and testing of composite structures.

Tanveer Ahmed is an Assistant Professor at the Department of Mechanical Engineering in HITEC University Taxila, Pakistan. He has received his Ph.D. in Mechanical Engineering from National University of Science and Technology Islamabad, Pakistan. He research interest is characterization and finite element analysis of composite materials.

Jung-il Song is a Professor and Dean of Mechatronics Engineering in Changwon National University, South Korea. He has received Ph.D. in Mechanical Engineering from POSTECH, South Korea. He is a known researcher in the fields of polymer composite materials, metal matrix composites.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Saghir, Q., ur Rehman Shah, A., Kamran Afaq, S. et al. Effect of machining parameters on surface quality and delamination of carbon/glass/epoxy hybrid composite material during end milling operation. J Mech Sci Technol 37, 2319–2324 (2023). https://doi.org/10.1007/s12206-023-0408-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-023-0408-7

Keywords

Search

Navigation