Authors: Ali Kuzu and Mustafa Bakkal
Milling operation is one the critical process in manufacturing of glass fiber reinforced polymer composites (GFRP) composite parts and their assembly due to the requirements of tight dimensional tolerances. In this study the effect of tool geometry and cutting parameters on machinability of GFRP were evaluated in end-milling process. This investigation was done by the evaluation of two cutting parameters, cutting speed and feed rate, and three tool geometries, rake angle, clearance angle and helix angle, with design of experiments concepts. 2-level full factorial design model was used in order to evaluate cutting parameters and tool geometry effect on cutting forces. A procedure developed to assess and optimize the chosen factor to attain minimum cutting forces. This procedure was consisting of normal probability plot, main effect plot, interaction plot and ANOVA analysis. The analysis results of this paper indicates that the feed rate recognized to make the most significant contribution to the machining of GFRP and the most effective tool geometry on machinability is the clearance angle.
Keywords: component; Composites, DOE, Machinability