Experimental Study and Artificial Neural Network Simulation of Cutting Forces and Delamination Analysis in GFRP Drilling

Abstract

This paper reports the results of measurements of cutting forces and delamination in drilling of Glass-Fiber-Reinforced Polymer (GFRP) composites. Four different types of GFRP composites were tested, made by a different manufacturing method and had a different fiber type, weight fraction (wf) ratio, number of layers, but the same stacking sequence. GFRP samples were made using two technologies: a novel method based on the use of a specially designed pressing device and hand lay-up and vacuum bag technology process. The study was conducted with variable technological parameters: cutting speed vc and feed per tooth fz. The two-edge carbide diamond-coated drill produced by Seco Company was used in the experiments. Cutting-force components and delamination factor were measured in the experiments, and photos of the holes were taken to determine the delamination. In addition, modeling of cause-and-effect relationships between the technological drilling parameters vc and fz was simulated with the use of artificial neural network modeling. For all tested GFRP materials, an increase in fz led to an increase in the amplitude of cutting-force component Fz. The lowest values of the amplitude of cutting-force component Fz were obtained with the lowest tested feed per tooth value of 0.04 mm/tooth for all tested materials. It was observed that materials produced with the use of the specially designed pressing device were characterized by lower values of the cutting-force component Fz. It was also found that the delamination factor increased with an increase in fz for all tested GFRP materials. A comparison of the lowest and the highest values of fz revealed that the lowest delamination factor increase was archived by the B1 material and amounted to about 12.5%. The error margin of the obtained numerical modeling results does not exceed 15%, so it can be concluded that artificial neural networks are a suitable tool for modeling cutting force amplitudes as a function of vc and fz. The study has shown that the use of the special pressing device during the manufacturing of composite materials has a positive effect on delamination.