Title: Regression modelling and optimisation of cutting parameters through Nelder-Mead simplex search and CCFD during drilling of sisal-glass/vinyl ester composites

Authors: S. Velumani; P. Navaneethakrishnan; S. Jayabal; R. Ramprasath

Addresses: Department of Mechanical Engineering, Velalar College of Engineering and Technology, Thindal, Erode, Tamilnadu, 638012, India ' Department of Mechanical Engineering, Kongu Engineering College, Perundurai, Erode, Tamilnadu, 638052, India ' Department of Mechanical Engineering, A.C. College of Engineering and Technology, Karaikudi, Tamilnadu, 630004, India ' Department of Mechanical Engineering, Sri Aravindar Engineering College, Sedarapet, Villupuram, Tamilnadu, 605111, India

Abstract: Drilling of holes in the assembly of structural frames of automobile and aircrafts are inevitable in order to make joining of parts. The drilling induced damage imparts reduced life and efficiency of parts. The present study attempts an effort to correlate drilling induced damage with drilling parameters during drilling on the Sisal-glass/vinyl ester hybrid composites. Diameter of drill, speed and feed rate were considered as significant factors and they control or minimise the drilling induced damages. Experiments were conducted under various cutting conditions as per design of experiments. Mathematical models for thrust force, torque and delamination factor were developed using non-linear regression equations. Optimisations of controlling parameters were done using Nelder-Mead simplex search method and central composite face centred design (CCFD). Analysis of variance (ANOVA) was used to study the effect of process parameters on drilling responses. The results revealed that the delamination can be effectively reduced in drilling of sisal-glass fibre composite materials by applying the lower feed rate values.

Keywords: fibre reinforced plastics; FRP drilling; delamination; polymer composites; sisal glass fibre composites; vinyl ester composites; hybrid composites; drill diameter; drill speed; feed rate; drilling-induced damage; design of experiments; DOE; mathematical modelling; thrust force; torque; CCFD; ANOVA.

DOI: 10.1504/IJMMM.2013.055118

International Journal of Machining and Machinability of Materials, 2013 Vol.14 No.1, pp.1 - 23

Received: 05 Sep 2011
Accepted: 06 Oct 2012
Published online: 26 Dec 2013 *

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