A Study on Optimizing Different Cutting Conditions Using Different Cutting Tools to Reduce Delamination in Drilling Kenaf Polymer Composite

Kee, Chia How (2020) A Study on Optimizing Different Cutting Conditions Using Different Cutting Tools to Reduce Delamination in Drilling Kenaf Polymer Composite. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Nowadays, the need of the natural fiber reinforced composite usage in industrial applications keeps increasing, however machining of these materials was facing various problem come up owing to deficient data and limited amount of study. This research project was to study on reducing delamination in drilling kenaf polymer composite using different cutting tools. Firstly, the theory and knowledge related to this research were studied and analyzed. CNC drilling machine, Johnford VMC-500 Vertical Machining Centers was used to perform the drilling operation. The workpiece used was kenaf polymer composite and three types of cutting tools used to perform the drilling operations were uncoated carbide DR30, coated carbide DR30 and uncoated carbide DR45 twist drills. The cutting speed was set in the range from 1000 to 2000 rpm while the feed rate was set in the range from 0.1 to 0.3 mm/rev. After the experiment being conducted, Dino-Lite AM4113ZT microscope was used to observe the delamination zone and the adjusted delamination factor was calculated and recorded. Lastly, Design of Experiments (DOE) was used to analyze the results and find out the optimum cutting parameters for this research. The results showed that the adjusted delamination decreased with the increase of the cutting speed and the decrease of the feed rate. Coated carbide DR30 was the best cutting tool for drilling kenaf polymer composite as the value of the adjusted delamination factor was the lowest with a value of 1.67778. For all the cutting tools, the cutting speed of 2000 rpm and the feed rate of 0.1 mm/rev was the optimum cutting parameters for the drilling operation in this research.