Title: Experimental investigation and FEA implementation on drilling of graphene reinforced GF/epoxy polymer nano composite laminate using coated and uncoated carbide drills

Authors: Bishnu Prasad Mishra; Debadutta Mishra; Pranabini Panda; Pragyan Senapati; Trupti Ranjan Mahapatra

Addresses: Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Mechanical Engineering Department, Government College of Engineering, Bhawanipatna, Odisha, 766003, India; Mechanical Engineering Department, SOA University, Bhubaneswar, Odisha, India ' Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Mechanical Engineering Department, Government College of Engineering, Bhawanipatna, Odisha, 766003, India; Mechanical Engineering Department, SOA University, Bhubaneswar, Odisha, India ' Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Mechanical Engineering Department, Government College of Engineering, Bhawanipatna, Odisha, 766003, India; Mechanical Engineering Department, SOA University, Bhubaneswar, Odisha, India ' Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Mechanical Engineering Department, Government College of Engineering, Bhawanipatna, Odisha, 766003, India; Mechanical Engineering Department, SOA University, Bhubaneswar, Odisha, India ' Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Mechanical Engineering Department, Government College of Engineering, Bhawanipatna, Odisha, 766003, India; Mechanical Engineering Department, SOA University, Bhubaneswar, Odisha, India

Abstract: The current study aims to explore the drilling characteristics of graphene-reinforced GF/epoxy nanocomposites via experimentation, validated by finite element analysis (FEA). Experiments involved drilling a [0/90]40s 10 mm thick laminate using 8 mm diameter uncoated and coated (TiN, TiAlN) solid carbide drills (2 flute, cone angle: 118°). Effects of coating, cutting speed, and feed rate on thrust force, torque, entry, and exit hole size were analysed. Uncoated drills exhibited the highest average thrust force (78.6 N) and torque (0.61 Nm) compared to TiAlN and TiN coated drills. TiAlN produced maximum average value of thrust force and torque of 48.4 N and 0.44 Nm, while TiN yielded maximum average value of thrust force and torque of 44.70 N and 0.35 Nm, respectively. Uncoated drills showed 27%-38% higher thrust force than TiAlN and 34%-48% higher than TiN under various cutting conditions. TiN coated drills exhibited the lowest thrust force and torque. Lower feed rates with higher spindle speeds reduced thrust force, minimising drilling-induced damage, offering valuable guidelines for high-quality drilling operations. The FEA predictions showed a maximum 10% error compared to experimental results for thrust force and torque under different drilling settings.

Keywords: drilling; nanocomposite; grapheme; thrust; torque; finite element analysis; FEA.

DOI: 10.1504/IJMMM.2024.141484

International Journal of Machining and Machinability of Materials, 2024 Vol.26 No.3, pp.193 - 222

Received: 19 Oct 2023
Accepted: 10 Jan 2024
Published online: 17 Sep 2024 *

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