an experimental investigation on surface morphology … · an experimental investigation on surface...

ANEXPERIMENTALINVESTIGATIONONSURFACE

MORPHOLOGYOFMACHINEDNANO‐COPPEROXIDEREINFORCED

EPOXYCOMPOSITE

1HASANALAMERI,2M.N.M.ANSARI

1,2CentreforAdvancedMaterials,DepartmentofMechanicalEngineering,CollegeofEngineering,UniversitiTenagaNasional,JalanIKRAM‐UNITEN,43000Kajang,Selangor,Malaysia,

Email:[email protected];[email protected]

ABSTRACT

Thispaperdealswithmachinabilityofnano‐copperoxide(nCuO)reinforcedepoxycompositeintermsofsurfacemorphologywithdifferentcompositionusingthe computernumericalcontrol(CNC)millingprocess.Composite’ssurface roughnessanddispersion of nCuO particles are the aspects of morphological research conducted. For the purpose of predicting theperformanceof machiningparametersandthequalityofproducts,surfaceroughnessisthecriterionanalyzed.Forthetestsinthisresearch,theevaluationofcuttingparametersarespindle speed(SS),feed rate(FR),anddepthofcut(DC).Inorderto studythemainchangesintextureofthemachinedsurfaceandtomakedecisionsontheoptimalmixed‐levelarrayofcutting parameters,ScanningElectronMicroscope(SEM)andsurfaceroughnessmeasurementwereconducted.Basedontheanalysisof variance (ANOVA) and signal to noise ratio (S/N)methods, itwas determined that the SS and FR parameters havesignificanteffectson the surfaceroughness.Hence,a bettersurfacequalitycanbeachievedbyvarying the levelofcuttingparameters.Moreover,thebetter surfaceroughnesswillbeachievedbyutilizingnCuOparticlesinthepolymermatrix. IndexTerms:Epoxymatrix,millingprocess,surfacemorphology,cuttingparametersandsurfaceroughness.

1.INTRODUCTION

In industrial accomplishment for lightermaterialswithgood properties, the fiber reinforced polymer (FRP)composites development is of significance for instancehighyieldstress, specialstiffnessandtensilestrength.Incertain applications, FRP composites are used for inmarine, transportation, and construction since they arelight weight, together with optimized mechanicalelements. The cost of manufacturing and a balancebetween their mechanical elements are accomplishedfrom these types of materials. Various processes areused on composite materials currently to have moreengineering operations. In addition, machining of theFRP composites is vital during the process as thesematerials are integrated into industrial performances.Themajorprocessismillingcompositestocomeupwithasuperiorsurfacealthoughchallengingbecauseoftheir strength and composition ratio. Davim et al. [1].Conductedaresearchofthemillingprocess intwokindsof glass FRP composites materials for tests of millingprocess. In milling process of carbon reinforced plasticcomposites,DavimandReis[2]analyzedparticularlythedamage and dimensional precision. In end‐millingprocess, Lanz et al. [3] experimented on themachinability of an aluminum reinforced epoxycompositeintermsofrapidtoolinguses.Astate–oftheart manufacturing process utilizing computer aideddesign (CAD) and computer aided manufacture (CAM)systemformachiningofcomplexpartsisalsoknownasComputer numerical control (CNC) milling [4] rof

efficiencyimprovementinCNCmillingprocess, Yih‐fongandMing‐der[5] testedtheTaguchi methodtocreateamaximum high speed CNC milling along with superiordimensionalquality.Also,Lin andKoren[6]workedonanadvancedprocessforafive‐axis.Forhighprecisionin machined surfaces, surface roughness is vital fortechnological product quality and for influences ofmanufacturingcostinCNCmilling.Toassessthesurfaceroughness, Benardos and Vosniakos [7] examineddifferentpracticesforthesurface roughness’prediction.OzcelikandBayramoglu[8]workedontheimprovementofthestatisticalmodelinginrapidendmillingprocessinterms of surface roughness. Eight levels of CNCmillingexperiments with full factorial design are used in thisstudy even though there are other ways of testing tominimize and optimize trial runs whenmany tests areneeded. A numberofparametershavedirecteffecton surface roughness, but usually are challenging tomeasure. For the improvement of the surface finish,cutting parameters like FR, SS, and DC are the mosteffective controllable parameters. This is so in themillingprocesswhich deen tobeoptimized[9]Inendmilling process KromanisandKrizbergs[10]discoveredlinks between machining parameters (federate, cuttingspeed,and DC)and3Dsurfaceroughness.SunandGuo[11] did many tests on cutting factors on titanium Ti–6Al–4Vforsurfaceintegrity. Wangetal.[12]conducteda studyon theeffectof thecutting parametersofbrasswork piece like FR, SS, and DC on surface roughness.Kalla etal. [13]wantedtomakepredictions intermsofthe cutting force for selecting optimum cutting

HASAN ALAMERI et al. DATE OF PUBLICATION: OCTOBER 07, 2014

ISSN: 2348-4098 VOLUME 2 ISSUE 7 SEP-OCT 2014

INTERNATIONAL JOURNAL OF SCIENCE, ENGINEERING AND TECHNOLOGY- www.ijset.in 1489

parameters to obtain minimum surface roughness incarbon FRPs. Gologlu and Sakarya [14] studied themaximum cutting factors in high speed milling of DIN1.2738mould steel. Oktem et al. [15] reported cuttingparameters maximization in end milling of Aluminium7075‐T6 to get the minimum surface roughness.Moreover, in end milling of hardened steel AISI H13,Ghani et al. [16] reported about optimum cuttingparameters for the purpose of studying the surfacetexture alterations, a precise model of morphologicalprocess need to be developed. The morphologicalstudies on surface roughness of machined compositematerials with SEM were used. Furthermore, themicroscopic pictures obtained from SEM are examinedthe spread of nano copper oxide particles into epoxymatrix. For the SEM, Lee and Dornfeld [17] studied inmicro end‐ milling of Aluminium 6061, surfaceroughnessSEM micrographs.Yaoetal.[18]3Drevealedsurface topography ofTB6 titaniumalloy inhigh‐speedmilling.2.MATERIALSANDMETHODS 2.1Preparationand fabricationofnCuO/epoxycompositesTodesign a composite, the categorization of compositebased on fiber and matrix is the first step. From thecombination of nCuO in to epoxy matrix of copperreinforced epoxy composite. etsaw particles frommachining processes from copper particles wererecycled. On the other hand, these copper particlespossess many dimensions. Later, nano copper oxideparticlesweremixedwith epoxymaterialsequally.Themeasurement of the composites’ part was conductedemployingdigital weightmeasurement.Table1depictsone sample of pure epoxy (PE) and two samples ofcopper/epoxy composites (ECuO0.4, and ECuO0.8),composition ratio for epoxy matrix and nano copperoxide particles. Lastly, after casting parts into threedifferent moulds the mixture was put under roomtemperature for 20 minutes in order to stabilize themixture and reducing the air bubbles trapped on thesurface of the mixture., then three samples of thepolymercompositeswereputinroomtemperaturewasleftatleast4daysinordertogetstable.ThreeproducedsamplesnamedasPE,epoxycopperoxideECuO0.4using(0.4) of copper particles and epoxy copper oxideECuO0.8 using (0.8) of copper particles for compositeswith100%pureepoxy,0.4and0.8ofcopperparticles.

Table‐1:ExperimentalmixingratioforcombinationofepoxyresinandhardenerwithnCuOparticles

2.2ExperimentalmethodIn this experiment, after selection a proper orthogonalarray, the milling processes were run via 3‐axis CNCmilling machine (OKUMA 45VX) under dry cuttingconditions using high strength substrate (HSS) 4‐flutecuttingtoolwith6mmdiameterwereusedinthemillingprocess.Formoreexplanations,anOKUMACNCmilling machine works with a spindle drive motor of 11kW together with 1800 r/min maximum speed. FR (A), SS(B), in the milling process and DC (C) were thecontrollable factors, whereas surface roughness isresponse. Two machining levels determined eachparameter (Refer to Table 2). The levels selectedwereobtained by evaluating the nature of composite’s partsand conducting a kind of trial experiment prior themajor process for the discovery of the best machininglevels. The findings revealed that for millingcopper/epoxy,FRmustnotbemorethan30mm/ mintoprovidethesmallestalterationsinsurfacetexture.Thus,10and20mm/minasFRlevelswereselectedproducingsimilar results. For assessing the surface roughness incompositeswithepoxymatrix,thefastmillingprocessispreferred for precise results Thus, as machining levels,the SS used 1000 and 1500 r/min DC with 0.4 and0.8mm were chosen subsequently to select themachining levels,milling process was employedwith 6mm‐HSS cutting tool by two level cutting parameters..The full factorial design of the cutting parameters isillustrated in table 3. Under dry cutting condition, theCNCmachiningwas employedbecauseof the flexibilityofthepartsabletoabsorbthecoolantliquid andleadstoalterations in mechanical elements. Figure 1 depictsmachinedsurfaceofnCuO(0.8)/epoxycomposite.

COMPOSITE

Epoxy

nCuO Resin Hardener

Type of nCuO used in sample

Weight fraction (wt%)

gram Weight fraction (Wt)

gram Weight fraction (Wt)

gram

Pure Epoxy(PE)

66.67 65.333 33.33 32.667 0 0

ECuO0.4 66.39 65.648 33.19 32.824 0.42 0.4

ECuO0.8 66.18 66.156 33.01 33 0.81 0.8




Table‐2:Machininglevelsofcuttingparameters

Table‐3:Fullfactorialdesignofthecuttingparameters

Feedrate(FR)(mm/min)

Spindlespeed(SS)(r/min)

Depthofcut(DC)(mm)

10 1000 0.420 1000 0.410 1500 0.420 1500 0.410 1000 0.820 1000 0.810 1500 0.820 1500 0.8

3.SCANNINGELECTRONMICROSCOPE(SEM)

A surface image canbeproducedby scanning itwith ahigh‐energy beam of electrons in a raster scan patternwith SEM, a type of electron microscope. The atomsinteract with the electrons that result in the surfaceproducing signals covering information concerning thesurface topography and spread of particles [19]. SEMdevice model Hitachi SU1510 with 10 kV acceleratingvoltage and 50 Pa condenser value was employed.Subsequently, thevarying textureofmachined surfacesofmixed‐level cutting parameters utilizing SEM imageswasused.SEManalyseswerethenconductedaccordingto themixed‐level arrays of cutting parameters chosenasinTable4toexaminethespreadofthecopperoxideand in machinednCuO/epoxycomposites, thevariationofsurfaceroughness.

Table‐4:Selectedmixed‐levelarrayofcuttingparameters

Experimental Level

Factors

Feed rate (FR)

mm/min

Spindle speed (SS) rpm

Depth of cut (DC) (mm)

1 10 1000 0.4

2 10 1500 0.8

3 20 1000 0.8

4 20 1500 0.4

Figure1:SampleofamachinednCuO(0.8)/epoxycomposite

4.RESULTS AND DISCUSSION

The morphological analysis of machined composites’surface through microstructure of SEM in terms ofpictures captured and quantitative values of surface roughness are analyzed in detail. Finally, the optimal mixed‐level array of these parameters which for moresuperiorsurfacequalitywillbedecidedonbyassessingtheimpactofcuttingparametersonsurfaceroughness. 4.1SurfaceroughnessmeasurementThe main applicable surface roughness amplitudeparameterswhichareusedinindustrycanbementionedas roughness average (Ra), root‐ mean‐ squareroughness (Rq),maximumpick‐to‐valley roughness (RyorRmax)and8‐pointmeanroughnessRz,perthometerS2 (MAHR) was employed for measuring anddocumentation purposes of the quantitative values ofsurface roughnessinmachinedsurfacesofnCuO/epoxy compositeofRaandRzstandards.4.2SurfacemorphologyofPEThedifferentclearlybetweenimagesofPEareshowninFigure2capturedbySEM. Subsequently,3 imageswith2000 X magnification and 1 image with 500 timesmagnificationwerecapturedforincreasedaccuracy.Theimage with mag=x500 was captured to illustratemeasured random into epoxy phase. The occurrence ofthis was in the process of filtering. Conversely, fromsieves’meshes,inconclusion,theminimumdesperationand high concentration in images (b) and (c), thisoccurrenceisobserved.Thus,forepoxymatrixinPE,Inaddition,theimagesshowthatthelowestroughnesswasachievedatparameterssettingofFRat10mm/rev,SSat1000rpmandDCat0.4mm(A1,B1,C1)andthehighestroughnesswas achieved at parameters setting of FR at20mm/rev,SSat1500rpmandDCat0.4mm(A2,B2,C1).ThemeaningisthattheparametersforinstanceSSandFRareextremelyeffectiveonsurface roughnessasrisingtheSSandFRthesurfaceroughnessrosedirectly.With the use of Minitab software, the major effects ofcuttingparametersonsurfaceroughnessarederivedbysignal to noise ratio(S/N). Smaller‐the‐better case is

Factors CuttingParameters Level1 Level2

A FR(mm/rev) 10 20

B SS(rpm) 1000 1500

C DC(mm) 0.4 0.8

DTooldiameter(TD)

(mm)6 6




employed for the assessment of optimized levelmachiningparametersresultinginminimumroughness.ThemaineffectsplotofS/NratioforcuttingparametersrunoncompositewhichincludespureepoxyisshowninFigure3.

It canbe seen that the SSwith1000rpm (B1)provideshigher S/N ratiowhich yields theminimum roughness.By thesamevein,FRwith10mm/rev(A1)and0.4mmDC(C1)alsoprovidelargerS/Nratioandminimumtheroughness. For better precision, the optimized cuttingparameterscouldbedeterminedlevel(1)oftestsbyA1,B1andC1.

(a) FR 10, SS 1000, DC 0.4 (mag=500X)

(b) FR 10, SS 1000, DC 0.4 (mag=2000X)

(c) FR 20, SS 1500, DC 0.4 (mag=2000X)

(d) FR 20, SS 1500, DC 0.8 (mag=2000X

Figure2: SEM images of machined surface of pure epoxy (PE)

2 01 0

3 . 6

3 . 2

2 . 8

2 . 4

2 . 01 5 0 01 0 0 0

0 . 80 . 4

3 . 6

3 . 2

2 . 8

2 . 4

2 . 0

Fe e d R a t e

Mea

n of

SN

rati

os

S p in d le S p e e d

D e p t h o f C u t

M a i n E f f e c ts P l o t f o r S N r a t i o sDa ta M e a n s

S ig n a l- to - n o is e : S m a lle r is b e tte r

Figure3: Main effects plot for S/N ratio in EP




4.3Surface morphology of ECuO0.4

Figure 4 depicts the differences between 3 capturedimagesbySEMforECuO0.4withnanocopperparticles.Furthermore, the image with mag=500X illustratesepoxymatrix.Inaddition,inthreeimages,thetextureofsurfaceroughnessforECuO0.4aresimilarandwithlessvariance, thus this occurrence can also verify theassumptioninfigure4forECuO0.4.Also,thisexperimentshowed the occurrence of the smallest roughnesshappenedatparameterswith20mm/revFR,1000rpmSS and 0.8mmDC (A2, B1, C2). Moreover, the highestroughnesswas achieved at parameters setting of FR at10mm/rev,SSat1000rpmandDCat0.4mm(A1,B1,C1).Thismeansthatbasedonthisstudy,thehigherlevel

ofcuttingparametersgiveminimumroughness. Figure5wasutilized in order to determine theparameters inorder to reach optimum capacity for machining ofsample consisting (0.4) copper particles. At level 2 (20mm/rev), the control factor of FR (A) gave minimumroughness and the largest S/N ratio. Correspondingly,the SS (B) at level 1 (1000rpm) also obtained the bestresponse andDC is has the lowest at level 2. Similarly,thelowestsurfaceroughnesswasachievedbyFRatlevel1 (0.4mm). Thus, the combination of levels that isoptimizedforthethreecontrolparametersissetasA2‐B1‐C1although the test showed thatSS (B)andDC (C)were not significant affecting surface roughnesscomparedtoFR(A).

(a) FR 10, SS 1000, DC 0.4 (mag=500X)

(b) FR 10, SS 1000, DC 0.4 (mag=2000X)

(c) FR 20, SS 1500, DC 0.4 (mag=2000X)

(d) FR 20, SS 1500, DC 0.8 (mag=2000X

Figure4: SEM image for ECuO0.4




2010

4.8

3.6

2.4

1.2

0.0

15001000

0.80.4

4.8

3.6

2.4

1.2

0.0

Feed Rate

Mea

n of

SN

rati

os

Spindle Speed

Depth of Cut

Main Effects Plot for SN ratiosData Means

Signal-to-noise: Smaller is better

Figure5:MaineffectplotforS/NratioinECuO0.4

3.4SurfacemorphologyofECuO0.8ForECuO0.8whichnanocopperoxideparticles,Figure6clearly depicts the differences between 3 imagescapturedbySEM.Also, the image (a)withmag==500Xdescribes the sameoccurrence inPE andECuO0.4. Thespreadofcopperparticlesintoepoxyphaseismorethanthe 2 other samples because of the weight of copper.Besides this, the cuttingparameters settingofFRat20mm/rev,SSat1000rpmandDCat0.8mm(A2,B1,C2)give the maximum surface roughness and parameterssettingofFRa20mm/rev,SSat1500rpmandDCat0.4mm(A2,B2,C1)givetheminimumsurfaceroughnessinECuO0.8.ThedesignedmajorimpactplotofS/Nratiofor

cuttingparameters in termsofECuO0.8 is illustrated inFigure7.Asaresultofthisfigure,theSSwith1500rpm(B2) obtains the higher S/N ratio leading to theminimum surface roughness. FRwith 10mm/rev (A1)andDCwith0.4mm (C1) can give larger S/N ratio andminimum roughness. Thus, the optimized cuttingparameters can be revealed as A1, B2 and C1.Toconclude,lowerlevelofFRandDCtogetherwithhigherlevelofSSgivegoodsurfacequalityECuO0.8.Inaddition,thisplotshowsclearlythatthethreecuttingparametershavesignificanteffectsonsurfaceroughness.

(a) FR 10, SS 1000, DC 0.4 (mag=500X)

(b) FR 10, SS 1000, DC 0.4 (mag=2000X)




(c) FR 20, SS 1500, DC 0.4 (mag=2000X)

(d) FR 20, SS 1500, DC 0.8 (mag=2000X)

Figure6: SEM images for ECuO0.8

2 01 0

1

0

-1

-2

1 5 0 01 0 0 0

0 .80 .4

1

0

-1

-2

Fe e d Ra t e

Mea

n of

SN

rati

os

S p in d le S p e e d

D e p t h o f C u t

M a in E f fe c ts P lo t fo r S N r a tio sDa ta M e a ns

S igna l- to -no is e : S m a lle r is be tte r

Figure7: Main effect plot for S/N ratio in ECuO0.8

4.CONCLUSION

Themorphologicalstudiesonthe machined surface of the pureepoxyandtwonCuOreinforcedepoxycomposites (PE, ECuO0.4, and ECuO0.8) were conducted. The SEMimages and quantitative roughness values fromroughness testerwith the effect of cutting parameters like FR, SS, and DC on the surface roughness of themachinedcompositeswere studied.Foradditionaldata,abriefstudywasconductedtodifferentiate thecaptured images’mainalterationsintextures.ForPEandECuO0.4the lowest roughness was reported that parameterssettingof10mm/minFR, 1000r/minSSand0.4mmDCat (A1, B1, C1), whereas for ECuO0.8 the cuttingparameters’ setting of 20mm/min FR, 1500 r/min SS and0.4mmDCat(A2–B2–C1)resultedintheminimum surface roughness which was justified by the resultsfromsurface roughnessmeasurementandSEManalysis.This investigation clearly explained that the surfacequality of machined nCuO/epoxy composite was quitesensitive tothedifferentlevelsofthecuttingparametersduring CNCmillingprocess.

ACKNOWLEDGEMENTS

Authors would like to thank the Universiti TenagaNasional (UNITEN),Malaysia for their constant supportand the assistance provided by Department ofMechanical Engineering, Universiti Putra Malaysia(UPM)arehighlyappreciated.

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[15]. Oktem, Hasan;Tuncay, Erzurumlu and FehmiErzincanli, "Predictionofminimum surface roughness inendmillingmoldpartsusingneuralnetworkandgeneticalgorithm",Materials & design,Vol.27, No. 9 ,2006, p735‐744.[16]. Ghani, J. A.; I. A., Choudhury; and H. H., Hassan,"ApplicationofTaguchimethodintheoptimizationofendmilling parameters",Journal of Materials ProcessingTechnology,Vol.145,No.1,2004,p84‐92.[17].Lee,KihaandDavidA.Dornfeld,"Astudyofsurfaceroughness in themicro‐end‐milling process”, LaboratoryforManufacturingandSustainability(2004).[18].Yao,Chang‐feng;Dao‐xiaWu;Qi‐chaoJin;Xin‐chunHuang; Jun‐xue Ren and Ding‐hua Zhang, "Influence ofhigh‐speedmilling parameter on 3D surface topographyand fatiguebehaviorofTB6titaniumalloy",Transactionsof Nonferrous Metals Society of China,Vol.23, No. 3,2013,p650‐660.[19]. Kaplan, Barry A.; Gary R. Goldstein; T. V.Vijayaraghavan and Ivy K. Nelson. "The effect of threepolishingsystemsonthesurfaceroughnessoffourhybridcomposites: a profilometric and scanning electronmicroscopy study”, The Journal of prostheticdentistry,Vol.76,No.1,1996,p34‐38.[20]. Yang, John L. and Joseph C. Chen, "A systematicapproach for identifying optimum surface roughnessperformance in end‐milling operations",Journal ofindustrialtechnology,Vol.17,No.2,2001,p1‐8.BIOGRAPHIES:

Hassan Alameri, received BSc.degree in materials and productionengineering from University ofTechnology,Baghdad,Iraq.Hejoinedthe Iraqi Ministry of WaterResources, Dams & ReservoirEstablishment as a mechanicalengineer.NowheisaMasterstudentat the Universiti Tenaga Nasional(UNITEN) Putrajaya, Malaysia.Interests’ composite material, Hisresearch interests in themanufacturing field of epoxycomposites using Nano reinforced,CNCmachiningandsmartmaterial.

Dr. M. N. M. Ansari, is a SeniorLecturer, Mechanical EngineeringUNITEN, Malaysia and VisitingResearch Scientist/ Researcher,RMIT University, Australia sinceAugust 2010. He has supervisedmore than 50 students UG Projectsand 10 PG research projects and 1Ph.D.He is also aReviewer forUPMJournal, Malaysia, Nanotech2012 &2013,USA, and International JournalofAutomationTechnology,Japan.




an experimental investigation on surface morphology … · an experimental investigation on surface...

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