Research highlights the significant impact of titanium dioxide and graphene nanofillers on the mechanical performance during the drilling process of glass fiber-reinforced composites.
Composite materials have surged to the forefront of engineering applications due to their exceptional mechanical properties. With applications across various sectors, including aerospace, there is an increasing demand for composites exhibiting enriched performance characteristics. A recent study has delved deep to reveal the effects of incorporating titanium dioxide and graphene nanofillers on the delamination behavior and thrust forces during the drilling of glass fiber-reinforced composites (GFRPC).
During drilling operations, the potential for damage such as delamination becomes quite pronounced, leading to reduced material performance. The ramifications of drilling-induced delamination are particularly serious; more than 60% of parts manufactured for aircraft are rejected due to delamination-related flaws. To mitigate these concerns, researchers, led by M.S. Harsha and his team, investigated composite materials incorporating 1 to 4 weight percent (wt%) of titanium dioxide and graphene nanofillers. This study sought to determine how varying these additional components could optimize drilling parameters and improve overall composite quality.
Employing advanced techniques, the team utilized various spindle speeds (600, 1200, and 1800 rpm), feed rates (30, 40, and 50 mm/min), and drill bit diameters (4, 6, and 8 mm). Each parameter was thoughtfully analyzed for its impact on thrust force and the resultant amount of delamination. High-resolution images captured during drilling were processed using MATLAB to determine delamination factors at the drilled holes.
The findings revealed compelling insights: thrust force diminished with higher spindle speeds and feed rates, showcasing optimal drilling conditions for improved performance. Interestingly, the researchers noted significant findings highlighting the complex interactions between the filler percentages and drilling parameters. The most notable result identified the best drilling configuration as utilizing a 4 mm diameter drill bit, at 1800 rpm spindle speed, and 50 mm/min feed rate.
"The presence of nanofillers significantly improved multiple performance characteristics during drilling," said the authors of the article, confirming the positive attributes offered by these additives.
Analyzing thrust forces unveiled pivotal trends; the study observed thrust forces reaching up to 98.1 N at lower RPMs and feed rates with higher percentages of fillers. Such insights are invaluable, as they indicate how fine-tuning these parameters can manage the energy exerted during drilling, potentially extending the lifecycle of drilling equipment.
When assessing delamination, maximum values were noted at varying drill bit diameters and spindle speeds, with specific combinations yielding results with over 18% reductions when utilizing composite materials infused with titanium dioxide and graphene. The investigations reasserted conclusions drawn by predecessors: the filler percentages impact delamination significantly, contributing to 30.05% at entry points and 20.22% at exit points.
Delamination at GT1 was revealed to be 18.47% lower compared to GT4, proving how effective adjustments to nanofiller compositions can be.
To summarize, the research establishes pivotal groundwork for enhancing the drilling performance of GFRPC. The application of grey relational analysis allowed for advanced optimization, pointing toward best practices within the industry. These findings signify not only a step forward for composite fabrication but open doors for future studies focusing on enhanced material performance through nanofiller integration. The studies suggest manufacturers can employ these findings to increase efficiency and reduce waste, directly impacting cost-effectiveness and material exploitation across engineering disciplines.
This comprehensive investigation exemplifies the need for continuous exploration within materials science, especially as industries increasingly seek sustainable and high-performance solutions.