Machinability study of carbon fibre reinforced polymer (CFRP) composites using design of experiment technique

TLDR

Surface delamination during milling of CFRP composites has not been previously analyzed with respect to machining parameters using response surface methodology. The study develops a response surface methodology model to quantify how cutting speed, feed rate, and depth of cut affect surface delamination when milling CFRP composites with a polycrystalline diamond‑coated carbide end mill. A three‑factor, three‑level face‑centered central composite design was employed, and Design Expert 8.0 performed regression and graphical analysis; the regression equation and response surface contour plots identified optimal variable values, while ANOVA confirmed the model’s validity. The resulting second‑order RSM model predicts delamination with 95 % confidence intervals across cutting conditions, enabling substantial time and cost savings.

Abstract

Abstract Purpose The purpose of this paper is to develop a mathematical model for the surface delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, feed rate and depth of cut) on the responses in milling of carbon fibre reinforced polymer (CFRP) composites with solid carbide end mill cutter coated with polycrystalline diamond. Design/methodology/approach Three factors, three level face-centered central composite design in RSM was employed to carry out the experimental investigation. The "Design Expert 8.0" software was used for regression and graphical analysis of the data collected. The optimum values of the selected variables were obtained by solving the regression equation and by analyzing the response surface contour plots. Analysis of variance was used to check the validity of the model and for finding the significant parameters. Findings The developed second-order response surface model is used to calculate the delamination of the machined surfaces at different cutting conditions with the chosen range with 95 per cent confidence intervals. Using such model, one can obtain remarkable savings in time and cost. Originality/value The effect of machining parameters on surface delamination during milling of CFRP composites using RSM has not been previously analysed.