Studying effect of fibre orientation in

GFRP laminates (+45 ,- 45 ,+-45)

by optimising process parameters
influencing machining force in milling

Avish Rawal (RA1411002010297)

Ishaan Bansal (RA1411002010158)
Rithvik Reddy (RA1411002010246)
Introduction
Milling is the most feasible machining process for producing slots and keyways with a well-
defined and high quality surface. Milling of composites is a complex task owing to its
heterogeneity and the associated problems such as surface delamination, fiber pullout,
burning, fuzzing and surface roughness. The milling process is dependent on the material
characteristics and the cutting parameters. An attempt is made in this field to investigate
the influencing cutting parameters affecting milling of composite laminates. Glass fibers
were used to fabricate laminates for experimentations. The milling operation was
performed with different feed rates, spindle speed and depth of cut. CNC Vertical milling
machine was used to mill slots on the laminates with different parameter combinations. A
milling tool dynamometer with data acquisition system was used to record the three
orthogonal components of the machining force.
Composites
A Composite material (also known as composition material or
shortened to composite) is made from two or more materials with
different physical or chemical properties, when combined, produces a
material with characteristics different from the individual materials.
The individual components remain separate and distinct in the finished
structure.
CLASSIFICATION OF COMPOSITES
Based on matrix constituent
Based on reinforcement form
Classification Based on matrix constituent
Polymer matrix composite
Polymer matrix composite consists of a polymer matrix along with a fibrous
reinforcing dispersed phase. Polymer matrix composites are popular due to
their low cost and easy fabrication methods.
Metal matrix composite
Metal matrix composites consists of a metal which is the matrix material and
is reinforced with particulate or fibers of a materials.
Ceramic matrix composite
Ceramic matrix composites consist of fibers as reinforcement which are
embedded in a ceramic matrix. They are reinforced either by continuous
(long) fiber or discontinuous (short) fiber.
Classification Based on reinforcement form
Particulate composites
Particulate Composites consist of a matrix material reinforced with a
dispersed phase reinforced material in the form of particles.
Fibrous composites
Short-fiber reinforced composites consist of a matrix material reinforced by a
dispersed phase material in form of discontinuous fibers (length <
100*diameter)
Long-fiber reinforced composites consist of a matrix material reinforced by a
dispersed phase reinforcement in form of continuous fibers.
Laminate composites
A fiber reinforced composite which consist of several layers of reinforcement
with different fiber orientations, is called multilayer composite or laminate
GLASS FIBER REINFORCED LAMINATES
Fiberglass is simply a composite consisting of glass fibers, they are of two types continuous or
discontinuous, contained within a polymer matrix; this type of composite is produced in the largest
quantities. The composition of the glass that is most commonly drawn into fibers (sometimes
referred to as E-glass). Fiber diameters normally range between 0.2mm and 2.0 mm. Glass is
popular as a fiber reinforcement material for several reasons:
1. It is easily drawn into high-strength fibers from the molten state of material.
2. It is readily available and it can be fabricated into a glass-reinforced plastic economically using a
wide variety of composite-manufacturing techniques.
3. It is relatively strong. When they are embedded in a plastic matrix, it produces a composite
having a very high specific strength.
4. When coupled with the various plastics, it possesses a chemical inertness that renders the
composite useful in a variety of corrosive environments.
MATERIAL FABRICATION AND PREPARATION
Mounting of vacuum pump - Vacuum pump of 1 HP capacity is used to
carry out the fabrication work
Matrix material - The main functions of Matrix material are it binds up the
fibers, transfers load to the 3reinforcement, provides rigidity and shape to
the structure, isolates the fibers for slow crack propagation, protects fibers
from wear and corrosion and also maintains surface quality. Ex:Araldite LY
556 epoxy resin with HY 951 hardener is used.
Reinforcement material - The main functions of reinforcement is to carry
70% to 90% of load and provide structural properties like strength, stiffness
and thermal stability etc.
Mylar sheets - It is used to get good mirror finish on the specimen.
Perforated release sheet/ Perforated film - It helps to hold the resin in the
laminate.
Procedure
1. Mould surface cleaning
2. Cut and position the reinforcement
3. Resin preparation
4. Fabrication
5. Demoulding the laminate
6. Cut the specimen
MECHANICAL PROPERTIES AND TESTING
Tensile strength - Specimens are positioned on the grips of a
Universal Test Machine at a specified grip separation and pulled until
failure.
Compressive strength - A fixture is used to align the specimen in the
wedge grips and the grips are therefore tightened. The wedges are
inserted into the compression fixture, and if an extensometer is being
used to measure strain, it is attached to the specimen. The specimen
is compressed to failure.
Flexural strength - The test method for doing the test usually
concludes a specified test fixture on a universal testing machine.
Details of the test preparation, and conduct affect the test results.
MILLING
Milling is the machining process where they use rotary end mill
cutters to remove material from a workpiece by advancing (or
feeding) in a direction at an angle with the axis of the tool.
To control the geometrical tolerance in composite laminates, it is
essential to perform machining operations. Milling is usually
performed in GFRP laminates to cut slots and groves. Milling is used
as a corrective operation to produce a well- defined and high quality
surface. Precision machining needs to be performed to ensure the
dimensional stability and interface quality.
METHODOLOGY OF TESTING
The experiments have been carried on GFRP laminates of 10mm thickness
end milling tool with 10 mm diameter. HSS tool is selected for
experimentation. A milling tool Dynamometer having three digital indicators
with a maximum range of 50 Kgf was used to acquire the three orthogonal
components of machining forces (F) such as Fx, Fy and Fz. The machining
were made on each GFRP laminate and the machining force was recorded
and analyzed for each slot with respect to the parameters such as feed rate,
speed and depth of cut.
PARAMETERS
1. Spindle Speed
2. Feed Rate
3. Depth of cut
LITERATURE REVIEW
N. Rajesh Mathivanan et al. An experimental investigation on the process
parameters influencing machining forces during milling of glass fiber
laminates. The feed rate and speed have statistical and physical significance
on the machining force on the work piece. Especially feed rate has more
influence on the machining force.

Naveen Sait et al. Optimisation of machining parameters of glass-fibre-

reinforced plastic (GFRP) pipes by desirability function analysis using
Taguchi technique. Desirability function in the Taguchi method for the
optimisation of multi-response problems is a very useful tool for predicting
surface roughness, machining force and tool wear in turning GFRP pipes.
THANK YOU