Abrasive Machining Characteristics and Prediction Model for Sisal/Polyester Sandwich Composite

ABSTRACT

This work focuses on optimization of abrasive machining parameters of the natural fiber reinforced sandwich composite, which is rarely reported in the literature. A sandwich made of vegetable fiber composite skins and polyvinyl chloride (PVC) foam of 80 gsm was machined for optimal conditions. The design of experiment and analysis were adopted to confirm the influence of machining parameters. The machining characters of bio-sandwich were compared with synthetic and hybrid sandwich panels to optimize the machinability of the target. The panels were manufactured through vacuum infusion bagging. The machining studies were done using the abrasive water jet cutting machine. The machining characteristics were optimized for the parameters and L18 Taguchi technique was employed in parameter optimization. Three controlled levels of machining parameters were chosen to be optimized: standoff distance (SOD), abrasive water jet pressure (JP), and nozzle traverse rate (TR). The response of kerf taper (KT), surface roughness (SR), and material removal rate (MRR) were investigated. It is observed that highest levels of these parameters gave minimum kerf taper and lowest levels produce lower surface roughness. The surface roughness and damage on the surface was observed using scanning electron microscopy (SEM). It Shows that flowing abrasive particle’s directional distortion noted at the foam regions due to their higher damping nature. The prediction model shows a good agreement with the experimental value.

摘要

这项工作的重点是优化天然纤维增强夹层复合材料的研磨加工参数, 这在文献中很少报道. 为获得最佳条件,对由植物纤维复合皮和80 gsm聚氯乙烯(PVC)泡沫制成的三明治进行了机加工. 采用实验设计和分析的方法,确定了加工参数的影响. 为了优化目标的可加工性,比较了生物夹层板与合成和混合夹层板的加工特性. 面板是通过真空输液袋制造的. 使用磨料水射流切割机进行了加工研究. 针对参数对加工特性进行了优化,参数优化采用了L18田口技术. 选择三个受控的加工参数级别进行优化; 隔离距离(SOD)、磨料水射流压 (JP) 和喷嘴移动率 (TR) 研究了切口锥度 (KT) 表面粗糙度 (SR) 和材料去除率 (MRR) 的响应. 据观察,这些参数的最高水平产生最小切口锥度,最低水平产生较低的表面粗糙度. 利用扫描电子显微镜(SEM) 观察表面粗糙度和表面损伤. 结果表明,流动磨料颗粒由于其较高的阻尼特性,在泡沫区域出现定向变形. 预测模型与实验值吻合较好

KEYWORDS:

• Sisal fiber
• composite
• pvc foam core
• awjm
• optimization
• prediction model

关键词:

• 剑麻纤维
• 混合成的
• 聚氯乙烯泡沫芯
• 优化
• 预测模型

Acknowledgments

This work is supported by Center for Composite Materials, Kalasalingam Academy of Research and Education, Anand Nagar/TN, India and also supported by UPM under GPB Grant-9668200. The authors would like to express their gratitude and sincere appreciation to Department of Aerospace Engineering, Faculty of Engineering, Universiti Putra Malaysia, and Laboratory of Biocomposite Technology, Institute of Tropical Forestry and Forest Products (INTROP), Universiti Putra Malaysia (HICOE), for the close collaboration in this research.

Disclosure statement

The authors declare no conflict of interest.

Authors’ Contributions

Conceptualization, Siva. I. and Chithirai Pon Selvan.; methodology, Siva. I.; formal analysis, Siva. I.; investigation, Avinash Shinde.; writing—original draft preparation, Avinash S Shinde and Siva. I; writing—review and editing, Mohamed TH Sultan, Lee Seng Hua and Yashwant Munde.

Additional information

Funding

The authors are grateful for the support of the U.S. Department of Biomaterials Research, Grant No. 2005-1234