The Influence of Cutting Conditions on Vibration in the Milling Process of Abaca-Glass Fiber Hybrid Composite

Abstract:

Machining processes on hybrid composite materials involve activities such as surface cutting, hole drilling and other cutting processes to achieve final shape and dimension of the composite product. There were several unexpected situations during the process, such as ununiform vibrations due to inconsistent of natural fiber structures and nonideal cutting conditions lead to progressive tool wear and low quality of the cutting surface. In this study, an experimental approach was conducted on the milling process of polyester matrix-based composites reinforced with abaca and glass fibers, produced through the press molding process. The milling process was utilized by a 10 mm diameter 4-flute carbide end mill cutter with a 45-degree helix angle. The study aimed to investigate the influence of cutting conditions (spindle speed, feed, and depth of cut) on vibration during the milling process of abaca-glass fiber composites. Three levels of each cutting parameters were determined based on cutting tool working capabilities, i.e. the spindle speed = 2000, 3000 and 5000 rpm, the feed = 0.004, 0.007 and 0.10 mm/tooth, and depth of cut = 1, 1.5 and 2 mm. The Design of Experiment (DOE) was constructed by Box-Behnken technique of Response Surface Methodology. The down milling process were conducted for all scenario of DOE, and the vibration was measured using a digital accelerometer. The results of the study indicated that vibration increased with the increase of spindle speed, feed, and depth of cut. The results show that the maximum vibration value (0.0206 m/s²) was obtained at a spindle speed of 5000 rpm with a feed of 0.07 mm/tooth and a depth of cut 2 mm. Meanwhile, the minimum vibration value (0.0143 m/s²) was obtained at the spindle speed 2000 rpm, feed 0.04 mm/tooth and depth of cut 1.5 mm.

• Periodical: Materials Science Forum (Volume 1149)
• Pages: 55-64
• DOI: https://doi.org/10.4028/p-rPD8BS
• Online since: May 2025
• Authors: Jihadul Qahhar, Mohd Iqbal*, Amir Zaki Mubarak, Laxman B. Abhang
• Keywords: Abaca Fiber, Composite, Cutting Condition, End Milling, Glass Fiber, Vibration

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