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This work aims to investigate the multiscale tribological behavior when drilling natural fiber composites by changing the tool-composite interface trough the modification of the tool coating. Drilling experiments were carried out on bidirectional flax fibers reinforced polypropylene resin using the same drilling tool geometry with three different c...
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Citations
... (Singh et al., 2020) suggested that during drilling of sisal-glass fiber reinforced polymer composites delamination, crack development, fibre breakage, fibre pull-out and matrix fibre debonding are the route cause for poor machining quality. (Chegdani & El-Mansori, 2018) carried out drillability study on flax fibre composites. They suggested that coated drill bit produced highest surface damage and resulted in poor surface roughness. ...
Advancements in technology and the compulsion to use environment-friendly materials have been challenging tasks for researchers for the past two decades. Researchers have been focusing on the utilization of plant fibers to produce good quality fiber-reinforced polymer/polyester composites for automobile, structural, and building applications. Researchers have been looking for high-quality and cost-effective drilling processes. The primary goal of this study is to identify optimal drilling conditions for CCFRP composite laminates, affecting thrust force and torque. This is achieved by manipulating drilling process variables using Taguchi’s Design of Experiments (TDOE), Analysis of variance (ANOVA), Response Surface Methodology (RSM), Desirability Function Analysis (DFA) and Artificial Neural Network (ANN). From the results, it was observed that the spindle speed of 2000 rpm, feed of 15 mm/min, point angle of 90°, fiber length of 6 mm, fiber volume of 30%, and fiber diameter of 7 microns gave the optimum results for obtaining minimum thrust force and torque. Further RSM revealed that an increase in fiber vol % and a decrease in spindle speed resulted in an increase in thrust force and torque. From DFA optimization results, the minimum thrust force of 24.0042 N and minimum torque of 0.8001 N-m was obtained. Finally, the experimental values of thrust force and torque were compared with the corresponding values predicted by the MLP-ANN model. The average error percentage for thrust force and torque was 1.75% and 6.56% respectively.
... Machining of biocomposites also shows significant sensitivity to the small variation of different material and/or process parameters such as the tool sharpness [20,21], the helix angle [22], the material temperature [23], the cutting speed and feed [24], and the depth of cut [25]. All these parameters affect the cutting contact stiffness that controls the involvement of shear, elastic deformation, plastic deformation, and friction mechanisms. ...
This work aims to study the cutting behavior of biocomposites under different controlled hygrothermal conditions. This investigation choice is motivated by the fact that natural plant fibers such as flax are characterized by their hydrophilicity which makes them able to absorb water from a humid environment. This absorption ability is intensified when increasing the conditioning temperature. The moisture diffusion process affects considerably the mechanical properties of the resulting composite, which causes many issues during the machining operations. In this paper, moisture diffusion, chip form, cutting and thrust forces, and the microscopic state of the machined surfaces are considered to explore the cutting behavior of biocomposites in the function of the hygrothermal conditioning time. Results reveal that moisture content in the biocomposite is significantly influenced by the conditioning temperature and the fiber orientation. The evolution of the moisture content and the increase of the fiber orientation affect both the chip morphology in terms of curling as well as the tool/chip interaction in terms of friction. The cutting behavior of flax fibers depending on hygrothermal conditioning time is then investigated using microscopic observations of the machined surfaces in addition to analytical modeling. An analysis of variance is used finally to quantify the observed results.
... The study indicates that altering the tool coating at various scale levels influences the tribo-mechanical behavior of the drilling operation. 55 Rezghi Maleki et al. studied non-destructive (NDT) tests to evaluate the delamination in the drilling of biofiber composites. They found that the image processing technique is the most suitable method of NDT to evaluate the delamination in NF composites. ...
Natural fiber composites are gaining interest in many industries, particularly the automotive and aerospace industries. One of the critical secondary activities required to produce a near‐perfectly shaped product is machining. The majority of product components had to be assembled before they could be used. This article reviews the various conventional and non‐conventional machining processes and its influential parameters investigated by various researchers. Non‐traditional machining is now proving to be a better choice than traditional machining. Non‐traditional machining has several advantages, including the absence of thrust force, chatter or vibration, minimal tool wear, and lower frictional heat. Delamination is the major issue occurring in the conventional machining processes like drilling. Researchers are more focused on the non‐conventional machining processes like abrasive water jet machining. Joining of natural fiber reinforced composites is another aspect discussed in this article. Adhesive joining is the most preferable joining method in the natural composites. The joining technique is also influenced by the intricacy of the materials to be bonded. Microwave joining and induction joining processes are the new methods of natural composites joining. This review also covers the various joining processes in the natural reinforced composite materials.
... It may be suggested that the presence of natural fibers produced this effect, which was likely due to the nonuniformity of their local properties, suggesting that limiting the time that the material is in contact with the tool via increasing the drilling speed might also reduce the extent of the damage. In practice, the intimate friction occurring during cutting can be modified by using tools with different surface coatings, as reported in [60] with respect to the drilling of flax fiber/polypropylene composites, indicating that drilling speed needs to be modified when applying different tools to natural fiber composites. On hemp-fiberreinforced polyester composites, when using a 5 mm tungsten carbide drill bit, the influence of cutting speed on delamination was confirmed, while it was suggested that it should not exceed 2000 rpm [61]. ...
This review highlights the influence of parameters on the drilling characteristics of biocomposites including natural fibers. The particular structure of natural fibers, including their hierarchized geometry, which potentially causes fibrillation, can result in an increased chance of irregularity of the hole and a more complex mode of delamination or, in general terms, damage to the composite. On the other hand, to attain an effective junction of the laminates in a structure, a nut–bolt procedure must be selected, which requires the performance of a drilling operation. This is becoming increasingly important since the fields of application for natural fibers and their variety have been steadily growing in the last few decades. Additionally, adequately performed drilling operations can address considerations related to circular economy. The drilling characteristics evaluated herein include thrust force, torque, surface roughness, and the delamination factor at the entry and exit of the drilling tool. The variation in tensile strength, stiffness, and strain propagation due to the presence of open holes of various sizes, the number of holes, the holes’ patterns, the effect of the type of fiber of the notches, the fiber architecture, and the fibers’ stacking sequence in biocomposites have also been discussed.
... Debonding, fiber pull-outs, and smearing were found in this experiment, however there were no delaminations at the entry or exit [157]. Chegdani and Mansori [158] reported the influence of different drilling tool coatings on the flax fiber reinforced PP composite. The experimental results reveals that the diamond coating shows a progressively worse behavior on machinability than the titanium diboride (TiB 2 ) coated tool. ...
Fiber-reinforced polymer (FRP) composites play a vital role in the production of structural and semi-structural components for engineering applications. The drilling process is a commonly employed machining process for FRP composites to join the FRP structural elements. Usually, the FRP composites possess a heterogeneous nature because of their multi-layered structure, hybridization, and the presence of multi-phase materials. Hence, common problems like delaminations, fuzzing, buckling, cracking, matrix and fiber burning occur during the drilling operations. These problems cause dimensional inaccuracy, poor surface finish, and tool wear and reduce the mechanical strength of the composites. The optimum drilling parameters (drill geometry, speed, feed, and depth of cut) selection for the specific materials is good to achieve effective drilling performance and better surface quality of the holes. Yet, little study has been done on how all of these factors affect the size of the drilled hole. The majority of drilling studies on FRPCs in the past have focused on how to improve the hole quality by maximizing processing conditions, and there has been little discussion on the correlation between drilling conditions, physical properties, and production techniques. This is what motivated to review the characteristics and properties analysis of FRP composites. As a consequence of this research, it is anticipated that scientists and researchers would place a greater emphasis on the drilling characteristic of the workpieces made from FRPCs than on other attributes. This review clearly presents an overview of FRP composites drilling that had progressed from 2000 to 2021. The analysis of different drilling conditions and parameters like thrust force, drill geometry, temperature, speed, and feed also includes the post-drilling analysis through delaminations, thermal damage, and surface roughness. Furthermore, the recent developments in carbon, glass, and natural fiber reinforced polymer composites are studied with both conventional and nonconventional drilling techniques. Based on the above studies, some future challenges and conclusions are drawn from this review.
... The influence of cutting depth was more on the machined surface, where the cutting forces were increased with increasing depth of cut. The cutting speed effect was significantly reduced because of thermal influence by plastic deformation and friction (Chegdani and El Mansori 2018a). The drilling and tribological behavior of flax/PP composite was affected by coated tool materials (diamond coated, titanium diboride coated, and uncoated tungsten carbide tool). ...
... Thus, the elemental flax fibers clear cut was observed on the machined surface, shown in Figure 7(a,d). The torn-off fibers without cutting are observed on the machined surface (Figure 7(c,f)) due to higher specific cutting energy induced by diamond-coated tools (Chegdani and El Mansori 2018a). The cutting tool geometries significantly affect machined surface quality in the case of drilled flax/PLA composite. ...
The natural, glass, and carbon fiber reinforced polymer composites are currently being replaced conventional materials due to their lower specific weight and superior strength properties. Natural fiber-reinforced polymer composites (NFRPCs) have grown in importance in real world applications recently due to a growing focus on the environmental and sustainability elements of engineering materials. The difficulty of machining FRP composites, which results in dimensional errors, poor product quality, and material damage, is due to their inhomogeneity, ease of deformation, and anisotropic nature. Moreover, this review gives an insight regarding recent developments and challenges that will help for upcoming researchers. The non-homogeneous properties and insufficient ductility of natural and synthetic fiber-reinforced composites have produced fracturing and discontinuous chips during the machining operations. The machinability of FRP composites depends on the constituents present in the composites. More delaminations were found in the natural fiber composites due to improper bonding and less compatibility with the polymer matrices, also the lower heat resistant property of the natural fibers causes serious problems during the machining process. Hence more studies are needed to decrease the thrust force and delamination damages in carbon, glass, and natural fiber reinforced polymer composites.
... The uncoated tool produced better machinability and the average surface roughness was found at around 15 nm which was less than other tools. 75 Different geometry of tools used for machining the unidirectional hemp fiber reinforced polyester matrix composite. Among three different tools, the center and parabolic tool geometry were convenient for the drilling process as these tools produced less thrust force and delamination at both sides of the composite. ...
Nowadays, the utilization of natural fiber reinforced composite has increased frequently. These natural fibers have significant features like low cost, renewable, and, more importantly, biodegradable in nature, making them to be utilized for various industrial sectors. However, the massive demand for natural fiber reinforced composites (NFRC), forces them to be machined and operated, which is required for countless areas in multiple industries like automotive, marine, aerospace and constructions. But before obtaining the final shape of any specimen, this specimen should come across numerous machining processes to get the desired shape and structure. Therefore, the present review paper focused on the various aspects during conventional and unconventional machining of the NFRC. It covers the work by exploring the influence of all input variables on the outcome produced after machining the NFRC. Various methodologies and tools are also discussed in this article for reducing the machining defects. The machining of the NFRC is found as a challenging task due to insufficient interlocking between the matrix and fibers, and minimum knowledge in machining characteristics and appropriate input parameters. Thus, this review is trying to assist the readers to grasp a basic understanding and information during the machining of the NFRC in every aspect.
... Le chapitre 1 a montré une forte sensibilité des matériaux agrocomposites à l'humidité. Ce [45,131,136]. La plaquette de coupe est composée de trois arrêtes utiles. Chaque arrête de coupe possède un angle de coupe de 20° et un angle de dépouille de 7°. ...
... Une étude de perçage sur des agrocomposites à fibres de lin bidirectionnelles et une matrice polypropylène (PP) montre que l'application d'un revêtement au foret endommage l'usinabilité de l'agrocomposite en augmentant l'énergie spécifique de coupe[131]. La hausse de la vitesse de coupe augmente l'énergie spécifique de coupe tandis que l'augmentation de la vitesse d'avance diminue l'énergie de coupe et réduit l'effet de la vitesse de coupe. ...
L’usinage des agrocomposites présente certains verrous scientifiques, notamment dans le cas des composites à fibres végétales longues et dont l’usinage reste une étape indispensable dans le processus de fabrication. La complexité de l’usinage des agrocomposites réside dans la structure cellulosique multiéchelle des fibres végétales qui les rend sensibles à l’humidité et capables d’absorber une quantité importante d’eau. Ceci impacte significativement les propriétés mécaniques des fibres ainsi que celles de la structure agrocomposite résultante. C’est dans ce contexte que ce travail de thèse propose une analyse à la fois expérimentale et numérique de l’effet hygrométrique sur l’usinabilité des agrocomposites. L’approche expérimentale a été réalisée en utilisant un dispositif instrumenté de coupe orthogonale et un agrocomposite en fibres unidirectionnelles de lin et matrice d’acide poly-lactique (PLA). Les échantillons d’agrocomposites ont subi un conditionnement hygrométrique par immersion totale dans l’eau. L’approche numérique a été développée via un modèle bidimensionnel micromécanique de coupe qui a été étendu à l’hygrométrie. Les résultats expérimentaux ont montré que la coupe des agrocomposites présente une dépendance considérable à l’hygrométrie et que différents mécanismes sont mis en jeu en fonction de l’échelle d’analyse et de la durée du conditionnement hygrométrique. Ces mécanismes induits sont observés à la fois au niveau du renfort fibreux végétal ainsi que les interfaces. L’approche numérique de modélisation a permis de reproduire correctement l’effet hygrométrique observé expérimentalement sur le comportement de coupe des agrocomposites après avoir implémenté des termes de dépendance à l’hygrométrie dans les lois de comportement du modèle numérique.
... For the drilling process, the analysis of the cutting edge radius effect is performed on BD flax FC (Chegdani and El Mansori, 2018). The cutting behavior of flax fibers during the drilling operation shown in Figure 10 is similar to that of the milling process presented previously in Erreur ! ...
The machinability of thermoplastic natural fiber composites is investigated in this article. An exploratory study is performed to investigate the effect of natural fiber type, fiber reinforcement structure, tool geometry, and process parameters on the cutting behavior of natural fibers under the usual machining processes. Results show how the cutting behavior if natural fiber is significantly sensitive to the variation of the different studied parameters. The article is concluded by technical recommendations to improve the machinability of natural fiber composites.
... Venkateshwaran and ElayaPerumal [10] presented that an increase in the feed rate and the spindle speed contributed to the rise of the delamination factor during drilling of epoxy composite reinforced with banana fibers. Chegdani and Mansori [11] found that the use of coated tools generated an increase in specific cutting energy in the drilling of bidirectional flax fiber reinforced polypropylene. The study [12] explored the machinability of two types of green composites (Sisal/PLA and Grewia Optiva/PLA). ...
... Figures 6 and 7 show that the specific cutting energy for the thrust force decreased with an increase in feed rate, but increased when the spindle speed increased. This result is in agreement with the literature [11]. It is also observed that an increase in the drill's diameter contributes to a decrease of the specific cutting energy for the thrust force ( Figure 6). ...
The machinability of composite materials depends on reinforcements, matrix properties, cutting parameters, and on the cutting tool used (material, coating, and geometry). For new composites, experimental studies must be performed in order to understand their machinability, and thereby help manufacturers establishing appropriate cutting data. In this study, investigations are conducted to analyze the effects of cutting parameters and drill bit diameter on the thrust force, surface roughness, specific cutting energy, and dust emission during dry drilling of a new hybrid biocomposite consisting of polypropylene reinforced with miscanthus fibers and biochar. A full factorial design was used for the experimental design. It was found that the feed rate, the spindle speed, and the drill bit diameter have significant effects on the thrust force, the surface roughness, and the specific cutting energy. The effects of the machining parameters and the drill bit diameter on ultrafine particles emitted were not statistically significant, while the feed rate and drill bit diameter had significant effects on fine particle emission.
