MACHINABILITY OF SiC AND AL2O3 PARTICLES FILLED SHORT GLASS FIBER REINFORCED EPOXY BASED COMPOSITES BY TURNING

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International Journal of Production Technology and Management (IJPTM)
Volume 13, Issue 1, January-December, 2022, pp. 32–43, Article ID: IJPTM_13_01_005
Available online at https://iaeme.com/Home/issue/IJPTM?Volume=13&Issue=1
ISSN Print: 0976- 6383 and ISSN Online: 0976 – 6391
DOI: https://doi.org/10.17605/OSF.IO/3HT8
© IAEME Publication
MACHINABILITY OF SiC AND AL2O3
PARTICLES FILLED SHORT GLASS FIBER
REINFORCED EPOXY BASED COMPOSITES BY
TURNING
VenkataKasiViswanadham Kolipakula1, Chandra Sekhara Kumar Aduru2,
Ravinder Reddy Pinninti3,
1
Mahatma Gandhi Institute of Technology, Telangana State, India
2
Jawaharlal Nehru Technical University - Hyderabad, Telangana State, India
3
Chaitanya Bharathi Institute of Technology, Telangana State, India
ABSTRACT
In recent years, advanced composite materials are switching to a large number of
components for its ease of manufacturing, low maintenance, high strength and light
weight. A continuous need was observed in many industries to develop high-strength
lightweight materials with excellent performance and efficiency in a variety of
applications. It was observed that during machining of composites, difficulties were
encountered such as higher cutting force, surface roughness and rapid tool wear. As a
result, the need for precise machining of composites has increased enormously. The
objective of the present work is to evaluate the cutting force and surface roughness of
metal powder (SiC and Al2O3) filled glass epoxy composites. Workpiece has been
fabricated using moulding technique. Machining of reinforced polymer short glass-
epoxy composite with filler particles are compared with those of unfilled glass-epoxy
composite. Turning experiments were performed on glass-epoxy composite under the
influence of SiC and Al2O3 filler metal powder particles and investigated under varying
cutting speed, feed-rate and depth-of-cut onconventional Lathe machine.The present
research work is expected to extend the scope of short E-glass epoxy composites with
filler particles in machining process. Turning experiments were compared with unfilled
glass epoxy composites under the same cutting parameters.
Key words: Composites, SiC, Al2O3, epoxy, random orientation, turning, cutting force,
surface roughness.
Cite this Article: VenkataKasiViswanadham Kolipakula, Chandra Sekhara Kumar
Aduru and Ravinder Reddy Pinninti, Machinability of SiC and Al2O3 Particles Filled
Short Glass Fiber Reinforced Epoxy Based Composites by Turning, International
Journal of Production Technology and Management (IJPTM), 13(1), 2022, pp. 32–43.
https://iaeme.com/Home/issue/IJPTM?Volume=13&Issue=1

Machinability of SiC and Al2O3 Particles Filled Short Glass Fiber Reinforced Epoxy Based
Composites by Turning
1. INTRODUCTION
In the present technological advancement era, the growing demand for economical and sturdier
materials with different accuracies and their applications are increasing. In recent years,
advanced composite materials are switching to a large number of components for its ease of
manufacturing, low maintenance, high strength and light weight.[6] A continuous need was
observed in many industries to develop high-strength lightweight materials with excellent
performance and efficiency in a variety of applications. The use of GFRP reinforced composites
in numerous automotive and aerospace industries, as well as its high performance
characteristics of light weight is of utmost significance. The incorporation of various nanosized
filler particles into polymer glass-epoxy composite will lead to performance improvement in
terms of mechanical properties and tribological features due to the change in wear mechanics.
Machining of fiber reinforced composites have been performed with carbide and HSS
cutting tool under various cutting conditions on Glass Fiber Reinforced Plastic (GFRP), Kevlar
Fiber Reinforced Plastics (KFRP), and Carbon Fiber Reinforced Plastic (CFRP)[4]. This is due
to their improved engineering qualities in comparison to non-reinforced metals and plastics.
The increased demand in the global market for high-performance products and lightweight
components also contributes to their rapid expansion in applications. When compared to metal
alloys and their metal matrix composites (MMCs) equivalents, FRP composites are known to
be lighter, stronger, stiffer, and have higher corrosion resistance.
In general, in the manufacturing processes, the traditional machining processes used for
metals is different compared to FRP composites. Machining of FRP composites are difficult
when machining with poor machined quality, this is because of the inherent non-homogeneous
microstructure of the composite. Often, mechanical performance of poorly machined FRP
composite exhibit severe wear and permanent failure of cutting tools which result in poor
machinability. Machining of reinforced glass-epoxy composites degrade and exhibit poor
machinability. Further Koeniget. al[17] unacceptable difficulties were encountered during
drilling of aramid fiber reinforced plastics, where high surface roughness of the cut surface was
obtained.
Delamination damage was observed on the cutting tool during machining of FRP composite
laminates. Increase in cutting force was recognised as major factor during machining of
laminate composite. During machining of composite materials, it was observed that the
roughness plays an important role in terms of tool wear and cutting force parameters which
were also affected by high heat generation at tool-workpiece interface. Friedrich [16] and Voss
et al. [15] studied that short E-glass fibre has better wear resistance when compared with glass-
epoxy composites.
Addition of filler particles in the reinforcement of glass-epoxy composites results in
reduction of coefficient of friction and wear during sliding condition[7-8]. In recent times,
micro, sub-micro, and nano-scale particles are used as filler materials in epoxy to result in
higher-performance composites through improved characteristics[1-3]. Numerous studies have
discovered that a wide range of micro and nano-inorganic fillers, such as Al2O3, SiC, ZnO,
TiO2, SiO2, nano-Si3N4and MnO2 can improve the tribological and mechanical properties of
polymer composites significantly [9-15]. Nanoparticles such as nano-Al2O3/polyimide, nano-
TiO2/epoxy, and nano-ZnO/poly tetra fluoro ethylene can also be used to improve the
tribological properties of composites. Further, it was observed that micro sized Al2O3/epoxy
composite exhibited low potential discharge resistance when compared to nano-micro
Al2O3/epoxy composite [16]. However, little research has been done on the effect of various
particles on random direction E-glass fabric. Compared to micro sized Al2O3 filler particles in
glass-epoxy composite, nano sized Al2O3 particles has emerged as potential fillers in polymer
composites as an advanced insulation material[5]. From the literature it was observed that little

VenkataKasiViswanadham Kolipakula, Chandra Sekhara Kumar Aduru and Ravinder Reddy Pinninti
research was carried out during machining of short E-glass fibre reinforced with filler particles.
Also the addition of superior performing filler particles enhances surface roughness and cutting
force during machining short/fiber polymer matrix.
The present work has investigated the influence of nano sized SiC, Al2O3 filler particles and
short E-glass fiber reinforced epoxy composite on cutting force and surface roughness. Turning
experiments were performed at varying cutting speed, feed rate and depth of cut parameters.
Further, the experimental results were compared with unfilled E-glass epoxy composite during
machining with selected cutting parameters.
2. EXPERIMENTAL PROCEDURE
2.1. Specimen Preparation
In the present study, short length random orientation E-glass fibre reinforced epoxy were used.
In the present study, the ratio of 2:1 epoxy resin and hardener is mixed properly to avoid bubbles
in the resin. 10 wt% of SiC and 5 wt% of Al2O3 filler particles are added to epoxy resin and
mixed properly to get a homogeneous mixture. The required quantity of random oriented short
E-glass fiber reinforced epoxy composite with filler particles were put in the mould. To
compare the experimental studies with unfilled glass-epoxy composite, another workpiece with
short fiber epoxy composite without filler particles is fabricated accordingly. The workpiece
specimen is moulded with the geometry of 36 mm in diameter and 250 mm in length. The
properly mixed short E-glass epoxy filled with SiC and Al2O3 was poured into the symmetric
metallic clamped duel piece mould containing a required cylindrical dimension. During the
pouring process, proper precautions were considered to quash the chance of entrapped air gaps.
For preliminary curing purpose, the mould was kept at room temperature for 48 hrs.
Fig1. Lathe machine
Figure 1
2.1.1. Turning Experiments
To investigate machinability of developed E-glass epoxy composite filled with SiC and Al2O3
particles, turning experiments were carried using carbide cutting insert at varying cutting speed,
feed rate and depth of cut considering cutting force and surface roughness as performance
indices. A detailed comparison has been made with unfilled E-glass epoxy composite specimen

using carbide cutting insert with an objective to improve machining performance. Photographic
view of Panther NC lathe machine with filled E-glass epoxy composite and lathe tool
dynamometer was shown in Figure1. Machining length was kept constant throughout the
experiments.
Table 1 Cutting parameters
Sl.No Level 1 Level 2 Level 3
Cutting speed (m/min) 150 200 250
Feed rate (mm/rev) 0.1 0.15 0.2
Depth of cut (mm) 0.5 1 1.5
Design method is used to perform the experiments under various parameters. In a factorial
design, a variable range is divided into levels between lowest and highest value parameters. A
three level full factorial design 3n
training data, where n is the number of variables. In the
present variables, cutting speed, feed rate and depth of cut has total 33
= 27 experiments. The
range of process parameters were presented in Table 2. Surface roughness was measured using
Mitutoya SJ210 surface profilometer.
Table 2 Design matrix
Sl. No Cutting Speed (m/min) Feed rate (mm/rev) Depth of cut (mm)
1 100 0.1 0.5
2 150 0.1 0.5
3 200 0.1 0.5
4 100 0.15 0.5
5 150 0.15 0.5
6 200 0.15 0.5
7 100 0.2 0.5
8 150 0.2 0.5
9 200 0.2 0.5
10 100 0.1 1
11 150 0.1 1
12 200 0.1 1
13 100 0.15 1
14 150 0.15 1
15 200 0.15 1
16 100 0.2 1
17 150 0.2 1
18 200 0.2 1
19 100 0.1 1.5
20 150 0.1 1.5
21 200 0.1 1.5
22 100 0.15 1.5
23 150 0.15 1.5
24 200 0.15 1.5
25 100 0.2 1.5
26 150 0.2 1.5
27 200 0.2 1.5
3. RESULTS AND DISCUSSION
3.1. Analysis of Surface Roughness
Figure2. show the average surface roughness as a function of cutting speed, feed rate and depth
of cut of machining filled and unfilled GFRP composites. The surface roughness was measured
at three different locations after cutting time of 2 min.

The results revealed that the surface roughness in not only a function of the machining
conditions but also on the work piece material with and without filler particles. From Figure2.
it was observed that the surface quality obtained for filled SiC and Al2O3 filler particles in E-
glass epoxy composite had better results than that of the GFRP composites with unfilled particle
composites. During all the cutting parameters, better surface roughness was observed for filled
particle GFRP composites. It was also observed that during all machining conditions for filled
and unfilled particle composites, surface roughness improves with increase in cutting speed.
With the increase in feed rate surface roughness increases. Whereas increase in depth of cut,
surface roughness increases. In addition, at higher cutting speed the BUE on cutting tool surface
turn out to be less, chip breakage decreases, and hence the quality of the machined workpiece
surface is achieved. This is expected because higher cutting speeds induce quite easier chip
removal from the workpiece resulting in a better surface finish of the workpiece.
Figure 2 Surface roughness at cutting speed = 100, 150, 200 m/min,(a) Feed = 0.1 mm/rev (b) Feed =
0.15 mm/rev, (c) Feed = 0.2 mm/rev (depth of cut = 0.5 mm)

Figure 3 Surface roughness at cutting speed = 100, 150, 200 m/min, (a) Feed = 0.1 mm/rev, (b) Feed
= 0.15 mm/rev , (c) Feed = 0.2 mm/rev (depth of cut = 1 mm)

Figure 4 Surface roughness at cutting speed = 100, 150, 200 m/min, (a) Feed = 0.1 mm/rev, (b) Feed
= 0.15 mm/rev (c) Feed = 0.2 mm/rev (depth of cut = 1.5 mm)
The above result reveals that the minimum surface roughness on the machining of GFRP
composites within the range of factor under investigation is 1.42 µm.
Surface roughness plays an important role in many areas and is a factor of great importance
in the evaluation of machining accuracy. Although many factors affect the surface condition of
a machined part, machining parameters such as cutting speed, feed rate and depth of cut have a
significant influence on the surface roughness for a given machine tool and work piece set-up.
It is known that the mechanism of cutting in GFRP composites is due to the combination of
plastic deformation, shearing and bending rupture.
During machining, at lower cutting speed, large material flow with the cut fibers has been
noticed which in turn produced high surface roughness, whereas at high velocity, the chips
mainly consist of less deformed matrix material and cut fibers.

The increase in feed rate increased the heat generation and hence, tool wear, which resulted
in the higher surface roughness. The increase in feed rate also increased the chatter and
produced incomplete machining at a faster traverse, which led to higher surface roughness. The
results shown prove that the roughness of the machined surface was highly influenced by the
feed rate. The depth of cut plays only a small role on composite machining process. From the
experimental results, it is observed that the surface roughness at a depth of cut 0.5 mm is higher
than that at a depth of cut of 1.5 mm.
Furthermore, the surface roughness increases as the feed rate increases. The surface
roughness produced on the GFRP work piece is mainly due to the feed rate. This is consistent
with the results from the study of Else Eriksen [18].
3.2. Analysis of Cutting Force
The machining force component is a crucial parameter during the evaluation of the performance
of any machining process. Several parameters like workpiece material, tool material and its
geometry have a considerable effect on machining force, which helps to estimate the energy
requirement of the machining process. During the machining process, the behaviour of average
machining force components under considered workpiece compositions with various cutting
parameters is shown in Figure3. It was understood that cutting speed significantly influences
the cutting force. The experimental results shown in Figure 3. that at high-speed cutting
conditions, the cutting force decreases causing reduction of shear strength at the machining
zone. Upon further increase in the machining speed, the friction coefficients at the tool-chip
zone on the cutting tool (at rake face) results in a decreased shear plane angle [6]. Therefore,
cutting force decreases at high-speed condition. As a result, the cutting speed was found to be
more significant effect in terms of inducing the machining force.

Figure 5 Cutting force at cutting speed = 100, 150, 200 m/min, (a) Feed = 0.1, (b) Feed = 0.15, (c)
Feed = 0.2 mm/rev (depth of cut = 0.5 mm)
Figure 6 Cutting force at cutting speed = 100, 150, 200 m/min, (a) Feed = 0.1 mm/rev, (b) Feed = 0.15 mm/rev
(c) Feed = 0.2 mm/rev (depth of cut = 1 mm)

Figure 7 Cutting force at cutting speed = 100, 150, 200 m/min, (a) Feed = 0.1 mm/rev, (b) Feed =
0.15 mm/rev , (c) Feed = 0.2 mm/rev (depth of cut = 1.5 mm)
Results also showed that machining force increases with increasing feed rate and depth of
cut in the machining process. This is due to the fact that, increase in feed rate and depth of cut
results in increased rate of plastic deformation at the primary shearing zone [12]. From the
obtained results it was observed that, during unfilled particles machining is associated with
enhanced friction, which leads to increased cutting temperatures, thereby increasing cutting
force. The high cutting forces acting in the shearing zones promote high friction with high heat
generation and consequently develop high temperature that accelerates tool wear. Whereas
during machining of glass-epoxy composite with SiC and Al2O3 filler particles, Al2O3 is acting
as a lubricant median and reduces the friction and generation of heat at tool-workpiece interface
zone. Thus results in decrease in cutting force compare to unfilled glass-epoxy composite.

4. CONCLUSIONS
It can be concluded from the results that both the output parameters cutting force and surface
roughness during machining of GFRP filled and unfilled particles are strongly influenced by
all the cutting parameters cutting speed, feed rate and depth of cut. Addition of SiC and Al2O3
filler particles to the E-glass epoxy matrix has a significant effect on the improvement of
machining properties. The surface roughness and cutting force properties has increased its
efficiency by 17.08% and 20.065% respectively, because of addition of 10% SiC particles and
5% of Al2O3 particles in short glass-epoxy composite. The improvement of machining
properties is because of better stress transfer and thermal resistance properties from fiber and
nano particles to the matrix, due to this existence of strong interfacial interactions between both
reinforcement and matrix, which depict the higher resistance to fibre pullout as compared to
fiber reinforced composites without SiC and Al2O3 filler nano particles.
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MACHINABILITY OF SiC AND AL2O3 PARTICLES FILLED SHORT GLASS FIBER REINFORCED EPOXY BASED COMPOSITES BY TURNING

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