ix
2.23 A Good Quality Hole
35 2.24
Drills, Twist 120˚, Twist 85˚, Brad, Dagger, Step 37
2.25 Feed Rate Effect on Maximum Thrust Force
38 2.26
Last Ply Thrust Force Comparison 38
2.27 Feed Rate Influence On Hole Surface Roughness
39 2.28
Result Expectation CFRP Composite 40
3.1 Technical documentation of tool grinding machine
44
3.2 Side view of tool grinding machine
44 3.3
Front view of tool grinding machine 45
3.4 Operating elements of tool grinding machine
45 3.5
Adjusting index head to clamp tool 46
3.6 Tool that been fabricate by tool grinding machine
46 3.7
To synchronize the diamond cutter and tool diameter 47
3.8 Testing using diamond cutter
47 3.9
Plastic tool sample been test by using diamond cutter 48
3.10 Testing fabricate plastic tool diameter 10mm
48 3.11
Material solid carbide has been choosing as tool materials 49
3.12 Measuring and cut solid carbide using EDM Die Sinking.
49 3.13
Material solid carbide diameter 6mm 50
3.14 Enter tool diameter 6mm inside tool clamp
50 3.15
Clamping solid carbide tool 51
3.16 From index head adjusting angle of tool clamping at 5º
51 3.17
Vertical adjustment grinding head to move the cutter grinding 52
3.18 Using diamond cutter grinding
52 3.19
First facet of tool after grinding 53
3.20 First facet of tool with 5º angle grinding
53 3.21
Release clamp and rotate the tool for grinding second facet 54
3.22 The way to operate tool grinding machine
54 3.23
Flow chart of final year project 56
3.24 CNC drilling machine 3
– axis 57
3.25 Portable surface roughness test mitutoyo sj - 30
58
x
3.26 Optical microstructure test
59 3.27
Quantification of delamination 59
3.28 Setup CFRP panel with dynamometer to measure cutting force
60
4.1 Normal plot of Residual surface roughness
64
4.2 Graph residual vs Predicted for surface roughness
64 4.3
Graph residual vs. run surface roughness 65
4.4 Model Graph 3D show for the point angle and facet surface roughness
65 4.5
Hole 1 delamination- in 0.70mm length 67
4.6 Hole 2 delamination
– in 0.79mm length 67
4.7 Hole 3 delamination
– in 0.45mm length 68
4.8 Hole 4 delamination
– in 0.61mm length 68
4.9 Hole 5 delamination
– in 0.60mm length 69
4.10 Hole 6 delamination
– in 0.51mm length 69
4.11 Hole 7 delamination
– in 0.15mm length 70
4.12 Hole 8 delamination
– in 0.22mm length. 70
4.13 Hole 9 delamination - in 0.45mm length
71 4.14
Normal plot of Residual for delamination – in
72 4.15
Graph residual vs. predicted for delamination – in
73 4.16
Graph residual vs. run for delamination – in
73 4.17
Model Graph 3D show for the point angle and facet delamination – in 74
4.18 Hole 1 Delamination
– out 0.67mm length 75
4.19 Hole 2 Delamination
– out 0.75mm length 75
4.20 Hole 3 Delamination
– out 0.46mm length 76
4.21 Hole 4 Delamination
– out 1.16mm length 76
4.22 Hole 5 Delamination
– out 0.49mm length 77
4.23 Hole 6 Delamination
– out 0.70mm length 77
4.24 Hole 7 Delamination
– out 0.85mm length 78
4.25 Hole 8 Delamination
– out 0.75mm length 78
4.26 Hole 9 Delamination
– out 0.16mm length 79
4.27 Normal plot of Residual for delamination
–out 80
4.28 Residual vs. Predicted for delamination
– out 80
xi
4.29 Residual vs. run for delamination
– out 81
4.30 Model Graph 3D show for the point angle and facet delamination
– out 81 4.31
Setup CFRP panel with Dynamometer 83
4.32 Cutting force measurement by using Dynamometer
84 4.33
Run 1, Tool 90º : 3 facet. 45.7764 N 85
4.34 Run 3, Tool 90º : 5 facet. 155.273 N
86 4.35
Run 4, Tool 100º : 3 facet. 188.995 N 86
4.36 Run 5, Tool 100º : 4 facet 227.173 N
87 4.37
Run 6, Tool 100º : 5 facet 194.244 N 87
4.38 Run 7, Tool 110º : 3 facet 212.738 N
88 4.39
Run 9, Tool 110º : 5 facet 199.768 N 88
4.40 Normal plot of Residual for cutting force
89 4.41
Residual vs. predicted for cutting force 90
4.42 Residual vs. run for cutting force
90 4.43
Model Graph 3D show for the point angle and facet for cutting force 91
4.44 Tool 9, 110º : 5 facet
93 4.45
Delamination – in hole 9. Average diameter 6.23mm
94 4.46
Delamination – out hole 9. Average diameter 5.935mm
95 4.47
Graph 3D desirability of solution tool selected 95
1
This chapter provides the background of the research. The research will focus on the improvement of new drill bit geometry for drilling CFRP composite with different fibre
orientation. The background of the research covers the development and current achievement of drill geometry for drilling CFRP composite. Moreover, the problem
statements followed by the objectives and scope of the project are included.
1.1 Background
