Abstract
Syntactic foams (SFs) finds its application in automobiles, aircrafts and underwater vehicles. Drilling is most frequently used machining operation for assembly of these composite structures. In the present investigation, an effort is made to analyse the effect of cutting speed (Cs), feed rate (fr), drill diameter (D) and filler content (F) on machinability characteristics in drilling glass microballoon (GMB) reinforced epoxy SFs. Machinability characteristics analyzed includes thrust force (Tf) and surface roughness (Sr). SFs are fabricated by dispersing 25, 35 and 45 vol.% of GMBs in epoxy resin. Experiments are carried out based on full factorial design (FFD) using TiAlN coated carbide drills. Experimental results show that Tfand Sr increases with increasing Cs. As fr increases, Tf increases but decreases the Sr. Increasing GMB content significantly reduces the Tf and Sr of developed SFs.
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