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Rajmohan T.,Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya | Palanikumar K.,Sri Sairam Institute of Technology
Materials and Manufacturing Processes | Year: 2011

Hybrid metal matrix composites (MMCs) find diversified applications in many engineering fields and are very important in the recent development of material science. The present article investigates the effect of thrust force in the drilling of hybrid MMCs using coated carbide drills. Materials used for the present investigation are Al 356-aluminum alloy reinforced with silicon carbide of size 25 microns and mica of an average size 45 microns, which are produced through stir casting route. Experiments are conducted on a vertical machining centre using the central composite design technique. A model is developed to correlate the drilling parameters with thrust force using response surface methodology (RSM). The results indicate that the developed model is suitable for prediction of thrust forces in drilling of hybrid MMCs. Analysis of the drilled surface of Al356/SiC-Mica composites was done using scanning electron microscope (SEM). The influence of different parameters on thrust force of Al356/SiC-Mica composites has been analyzed through contour graphs and three-dimensional (3D) plots. © 2011 Taylor & Francis Group, LLC.

Rajasekaran T.,SRM University | Palanikumar K.,Sri Sairam Institute of Technology | Vinayagam B.K.,SRM University
Production Engineering | Year: 2011

In recent days, carbon fiber reinforced polymer (CFRP) composites play a vital role in various engineering and technological applications. They are replacing conventional materials due to their excellent properties. Tubes made of these materials are made up of either hand layup process or filament winding processes and are widely used in aircraft, automobile, sports industries, etc., The objective of this study is to examine the influence of machining parameters combination so as to obtain a good surface finish in turning of CFRP composite by cubic boron nitride (CBN) cutting tool and to predict the surface roughness values using fuzzy modeling. The results indicate that the fuzzy logic modeling technique can be effectively used for the prediction of surface roughness in machining of CFRP composites. © 2011 German Academic Society for Production Engineering (WGP).

Krishnamoorthy A.,Sathyabama University | Rajendra Boopathy S.,Anna University | Palanikumar K.,Sri Sairam Institute of Technology | Paulo Davim J.,University of Aveiro
Measurement: Journal of the International Measurement Confederation | Year: 2012

Carbon Fibre Reinforced Plastic (CFRP) composite materials have potential applications in various domains. In machining, drilling is essentially required to join different structures. But CFRP drilling poses many problems that decrease the quality of holes. In this paper, Taguchi's L 27 orthogonal array is used to perform drilling of CFRP composite plates. To improve the quality of the holes drilled, the optimal combination of drilling parameters is chosen using grey relational analysis. Grey fuzzy optimization of drilling parameters is based on five different output performance characteristics, namely, thrust force, torque, entry delamination, exit delamination and eccentricity of the holes. Analysis of variance (ANOVA) is used to find the percentage contribution of the drilling parameters and found that feed rate is the most influential factor in drilling of CFRP composites. © 2012 Elsevier Ltd. All rights reserved.

Rajmohan T.,Tamil University | Palanikumar K.,Sri Sairam Institute of Technology
International Journal of Advanced Manufacturing Technology | Year: 2013

The present paper deals with the modeling and analysis of machining responses such as the thrust force, surface roughness, burr height, and tool wear in the drilling of hybrid metal matrix composites using carbide, coated carbide, and polycrystalline diamond drills. Experiments are conducted on Al 356 aluminum alloy reinforced with silicon carbide of size 25 μm and mica of size 45 μm. Machining parameters such as spindle speed, feed rate, and weight percent of silicon carbide are chosen as the numerical factors; the drill material is considered as the categorical factor. An experimental plan of a four-factor (three numerical plus one categorical) D-optimal design based on the response surface methodology is employed to carry out the experimental study. The results indicated that the predicted values through the developed model are well in agreement with the experimental results. The results also indicated that the method used is effectively applied for the modeling and analysis of drilling parameters in drilling hybrid metal matrix composites. © 2012 Springer-Verlag London Limited.

Palanikumar K.,Sri Sairam Institute of Technology | Latha B.,Sri Sairam Engineering College | Senthilkumar V.S.,Anna University | Davim J.P.,University of Aveiro
Materials and Manufacturing Processes | Year: 2012

Glass fiber-reinforced polymer (GFRP) composite materials are an economic alternative to the engineering materials because of their superior properties. The present work focuses on the use of Grey relational analysis for optimizing the drilling parameters on the surface roughness and the thrust force in the drilling of GFRP composites. Taguchi's L 9, 3-level orthogonal array is used for the experimentation. Optimal machining parameters are determined by the Grey relational grade obtained from the Grey relational analysis for multiperformance characteristics. Experimental results show that the machining performance in the composite machining process can be improved at optimal drilling conditions. © 2012 Copyright Taylor and Francis Group, LLC.

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