International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2306

Structural Analysis Of Delamination
Of Composite Materials Using Vertical
Milling Machine (GFRP)
B.Bindu madhavi
#1
, S.Suresh
*2
1
M. Tech-(CAD-CAM), Siddharth Institute of Engineering and Technology, Puttur

2
Associate Professor, Siddharth Institute of Engineering and Technology, Puttur


ABSTRACT

The composite materials were available in the olden
days in many forms there has been a tremendous research
in the area because of its high strength to weight ratio
especially in structural applications. This project deals
glass fibre reinforced polymer (GFRP) composite.
Fibre glass reinforced plastic are made of a plastic matrix
reinforced by fine fibers of glass. GFRP is light weight,
extremely strong,and robust material.
Machining involves the removal of any extra or unwanted
material. The maerial removal mechanism of FRP is very
difficult as compared with metals due to their homogeneity
and anisotropy.
The delamination that occurs during milling
severly influences the mechanical charecterstics of the
material. In order to avoid these problems it is necessary to
determine the delamination occurring due to machining
operation. In order to understand the effects of process
parameters on the delamination a large number of
machining experiments have to be performed and analyzed
using FEM model. Using FEM model the desired cutting
and material parameters for minimized appearance of
delamination has been developed.
Key Words: GFRP, PRO/E(Creo parametric 1.0),
ANSYS, Finie element analysis.

I. INTRODUCTION
A) composite
A composite material is an
anisotropic, heterogeneous medium, made by
combining two or more materials with
differing properties. Properties of the
composite are different from those of the
constituent materials. The components of the
composite do not merge completely in to each
other and can be physically identified along
with the interface between them. The
properties of the interface also contribute to
the properties of the composite.
B) Types of Fiber:
Carbon Fiber
Glass Fiber
Aramid (Kevlar) Fiber
Grades of glass fiber of which the
following are the most common:
E-glass - Good electrical insulator and
high strength.
C-glass - Good chemical corrosion
resistance.
S-glass - High silica content with high
temperature performance, high
strength and stiffness military grade.
R-glass - Civil version of S-glass.
A-glass - High alkali content for
chemical resistance.
D-glass - Low dielectric and low
density.
L glass - High lead content for
radiation protection.
Glass fiber is available in the
following forms
1. Continuous Fiber
2. Chopped strands
3. Woven


International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013
ISSN: 2231-2803 http://www.ijcttjournal.org Page 2307
Fig 1 : Continuous Fiber

Fig 2 : Chopped Strands


Application of composite material:
The general application and properties of
composites are listed in Table

Table 1: The general application and properties
of composites

II. DELAMINATION
Delamination is defined as the
separation of the layers of material in a
laminate. Delamination can occur at any
time in the life of a laminate for various
reasons and has various effects. It can affect
the tensile strength performance depending on
the region of Delamination. Among the
various defects that are caused by drilling,
Delamination is recognized as the most
critical. Other defects are spalling and fiber
pullout, but Delamination can result
in a
reduction in the durability of the composite
material and can cause a reduction in the
bearing strength of the material and the
structural integrity, resulting in performance
issues. The Delamination in composite are
shown in Fig1.4.
Delamination factor is defined by ratio
of maximum diameter (of damaged zone
around hole) to actual diameter.
Delamination factor =D
max
/D
actual

Where
D
max
is damaged diameter D
actual

real diameter to be machined




Application Properties
Aerospace
Low weight ,high strength,
High modules.
Chemical/Marine Corrosion resistance
Automobile
Formability and tailor ability of polymer
composites
High temperature
application
Ceramic composites
Modulu
s of
elasticit
y

Modulus
of
elasticity

Bulk
modulus

Poiss
ons
ratio
Allowable
tensile stress

Allowable
tensile stress
(X-
directio
n) 48
GPa

(Y-
direction
) 12
GPa

6.0 GPa 0.25
(X-direction)
550 MPa

(Y-direction)
34 MPa

International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013
ISSN: 2231-2803 http://www.ijcttjournal.org Page 2308
Table 2: Specimen-I Material properties of
GFRP

Table 3: Specimen-II Material properties of
GFRP


Fig 3: Modeling of end milling


Fig 4: Modeling of GFRP specimen-I


Fig 5: Modeling of GFRP specimen-II


Fig 6: Specimen- I Meshing of GFRP



Fig 7: Specimen- II Meshing of GFRP
Modulus
of
elasticity

Modulus
of
elasticity

Bulk
modulus

Poissons
ratio
Allowable
tensile
stress

Allowable
tensile
stress
(X-
direction
) 75
GPa

(Y-
direction)
15 GPa

9 GPa 0.25
(X-
direction)
226.09
MPa

(Y-
direction)
25 MPa

International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013
ISSN: 2231-2803 http://www.ijcttjournal.org Page 2309
fig 8: Layers of GFRP specimen-I
fig 9: Layers of GFRP specimen-II
III. RESULTS AND DISCUSSION :

Fig 10: Nodal solution for GFRP specimen-I in
end milling

Fig 11: Delamination of GFRP specimen-I in
end milling

Fig 12: Nodal solution for GFRP specimen-II in
end milling

Fig 13: Delamination of GFRP specimen-II in
end milling

IV. COMPARISONS OF EXPERIMENTAL AND
SIMULATION RESULTS
The results obtained from the experimental
testing and simulations have been compared
are shown in the table 3.7. It has been found
out that the discussed FEA model results are
close to be experimental results.
Specimen Delamination in
experimental results
(mm)
Delamination in
FEA results
(mm)
I 1.48 1.37
II 1.50 1.26
Table 4 : Comparisons of experimental and
simulation results

V. CONCLUSION

The Delamination that
occurs during milling severely influences the
mechanical characteristics of the material. In
order to avoid these problems it is necessary to
determine the Delamination occurring due to
machining operation. In order to understand
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013
ISSN: 2231-2803 http://www.ijcttjournal.org Page 2310
the effects of process parameters on the
Delamination a large number of machining
experiments have to be performed and
analyzed using FEM model. Using FEM
model the desired cutting and material
parameters for minimized appearance of
delamination has been developed. It has been
found out that the discussed FEA model
results are close to be experimental results.
The 3D FEM models are applied to milling
and after simulations it is adaptable to industry
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