Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Abstract

Machining of plastic materials has become increasingly important in any engineering industry subsequently the prediction of cutting forces. Forces quality has greater influence on components, which are coming in contact with each other. So it becomes necessary to measure and study machined forces and its behavior. In this research work, experimental investigations are conducted to determine the effects of cutting conditions and tool geometry on the cutting forces in the turning of the unidirectional glass fiber reinforced plastics (UD-GFRP) composites. In this experimental study, carbide tool (K10) having different tool nose radius and tool rake angle is used. Experiments are conducted based on the established Taguchi’s technique L₁₈ orthogonal array on a lathe machine. It is found that the depth of cut is the cutting parameter, which has greater influence on cutting forces. The effect of the tool nose radius and tool rake angles on the cutting forces are also considerably significant. Based on statistical analysis, multiple regression model for cutting forces is derived with satisfactory coefficient (R²). This model proved to be highly preferment for predicting cutting forces.

Key words： unidirectional glass fiber reinforced plastics (UD-GFRP) composites; machining; cutting forces (tangential; feed and radial force); ANOVA; regression modeling; carbide tool (K10)

Acknowledgements

The author is very grateful to Dr. Meenu Gupta, Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, India, and Dr. P.S. Satsangi, Department of Mechanical Engineering, PEC University of Technology, Chandigarh, India, for the support rendered. The authors are indebted to Maharashtra Engineering Industry, India (P) Limited, Satara Maharashtra for supplying the UD- GFRP rods used in this work.

Nomenclature

b0, b1, b2,b3 a, b, c, d x0, x1, x2, x3 Ft Ff Fr A B C D E F K η y ϵ Ŷ χ2

Estimates of parameters Exponentially determined constant Logarithmic transformations of machining parameters Tangential force/kg Feed force/kgf Radial force/kgf Tool nose radius/mm Tool rake angle/(°) Feed rate/(mm∙rev-1) Cutting speed/(m∙min-1) and rpm Cutting environment Depth of cut/mm Constant Cutting force response Measured cutting force Experimental error Estimated response based on second order model/kgf Chi-square

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