DOE coupled MLP-ANN for optimization of thrust force and torque during drilling of CCFRP composite laminates

Abstract

Advancements in technology and the compulsion to use environment-friendly materials have been challenging tasks for researchers for the past two decades. Researchers have been focusing on the utilization of plant fibers to produce good quality fiber-reinforced polymer/polyester composites for automobile, structural, and building applications. Researchers have been looking for high-quality and cost-effective drilling processes. The primary goal of this study is to identify optimal drilling conditions for CCFRP composite laminates, affecting thrust force and torque. This is achieved by manipulating drilling process variables using Taguchi’s Design of Experiments (TDOE), Analysis of variance (ANOVA), Response Surface Methodology (RSM), Desirability Function Analysis (DFA) and Artificial Neural Network (ANN). From the results, it was observed that the spindle speed of 2000 rpm, feed of 15 mm/min, point angle of 90°, fiber length of 6 mm, fiber volume of 30%, and fiber diameter of 7 microns gave the optimum results for obtaining minimum thrust force and torque. Further RSM revealed that an increase in fiber vol % and a decrease in spindle speed resulted in an increase in thrust force and torque. From DFA optimization results, the minimum thrust force of 24.0042 N and minimum torque of 0.8001 N-m was obtained. Finally, the experimental values of thrust force and torque were compared with the corresponding values predicted by the MLP-ANN model. The average error percentage for thrust force and torque was 1.75% and 6.56% respectively.

Keywords:

• Composite laminates
• drilling
• thrust force
• torque
• Taguchi’s design of experiments
• response surface methodology
• desirability function analysis
• artificial neural network

Reviewing Editor:

• Pham D T
• University of Birmingham
• United Kingdom

Subjects:

• Technology
• Engineering & Technology
• Manufacturing Engineering
• Manufacturing Technology
• Machine Science & Technology
• Production Engineering
• Manufacturing Engineering

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Notes on contributors

Sawan Shetty

Dr. Sawan Shetty Assistant Professor from Department of Mechanical and Industrial Engineering , Manipal Institute of Technology Manipal, Dr. Shetty is a an expert in Electrospinning, Synthesis and application of nanomaterials. His major research is focused on Functional nanofibers and composite materials.

Raviraj Shetty

Dr. Raviraj Shetty is a senior Professor from Department of Mechanical and Industrial Engineering, Manipal Institute of Technology Manipal. His area of expertise are Cryogenic Lubrication, Difficult to Machine Materials, Advanced Composite Materials, Tribology in Metal Cutting, Statistical Tool for Metal Cutting, Conventional and Non-conventional Machining of Composite Materials; Soft Computing, Natural Fiber Reinforced Polymers etc. He has more than 1000 citations from above 100 publications from various reputed International Journals.

Rajesh Nayak

Dr. Rajesh Nayak is a senior Associate Professor from Department of Mechanical and Industrial Engineering , Manipal Institute of Technology Manipal. His area of expertise include Manufacturing Engineering, Composite Materials, Machining of Materials, Natural Fiber Composites, Cryogenic Machining of Elastomers.

Adithya Hegde

Adithya Hegde Research Scholar from Department of Mechanical and Industrial Engineering, Manipal Institute of Technology Manipal. His area of interest and experience include and not limited to Advanced Manufacturing Methods, Refractory Ceramic/Metal composites, Natural Fiber Reinforced Polymer Composites, Sustainable Manufacturing, Artificial Neural Networks, Lubrication Systems & Cryogenics, Elastomer Machining, Statistical Design of Experiments etc. In a short research career of 3 years at MIT, Manipal he has published 14 Peer reviewed International Journals with 50+ citations.

Uday Kumar Shetty S. V.

S. V. Uday Kumar Shetty Professor is a senior Assistant Professor from Department of Mechanical and Industrial Engineering, Manipal Institute of Technology Manipal. His area of expertise include Industrial Engineering; Engineering Management, Facility Planning and Design; Work Systems Engineering.

Sudheer M.

Dr. Sudheer M Professor, Dept of Mechanical Engineering, St Joseph Engineering College, Mangaluru. His area of expertise are Polymer Composites, Metal Matrix Composites, Finite Element Techniques.