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ABSTRACT
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indicating that the model chosen is well in agreement with the experimental
results. Another accurate modeling approach, namely, adaptive neuro fuzzy
inference system (ANFIS) is applied for various other machining operations
in composite materials and hence applied for drilling in the present study.
ANFIS is based on a first-order Sugeno fuzzy inference model. A
more accurate model relating the drilling parameters and each response can be
obtained using ANFIS. The ANFIS models are obtained for all the six
responses chosen in the present study. To measure the goodness of fit of the
ANFIS model, R-Sq value, average training error in %, root mean square
error (RMSE) and mean absolute error (MAE) values are chosen as
performance factors. The evaluation of such performance factors are carried
out for four different membership functions and are repeated for five different
numbers of iterations. The best membership function and the number of
iterations are found for all the responses using the minimum values of average
error, RMSE and MAE values and an accurate ANFIS model is thus obtained.
On comparison, it is found that the responses predicted using ANFIS models
are close to the experimental values than that of regression models.
Grey relational analysis is used to optimize the drilling parameters
with a small set of database. The relational analysis is further explored using
grey fuzzy approach and the response tables and response graphs are plotted
that shows the most influential parameters and optimal drilling conditions.
Grey fuzzy analysis indicate that the optimal drilling conditions are high
speed of 3000 rpm, low point angle of 100 and low feed rate of 100 mm/min
for the experiments conducted using all the three drill tool materials. The
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response values are predicted for the optimal drilling conditions and
compared with that of corresponding experimental values and the initial
values.
The drilled holes are observed and certain drilling induced damages
are identified such as, delamination at the entry and exit planes, fiber pull-out,
spalling and fuzzing. Of all these damages, delamination is found to be the
major one and hence the mechanism of drilling is explored to understand the
cause for delamination. Thrust force is found to increase as the drill advances
into the work piece and reaches maximum as the drill tool touches the last
layer of the CFRP composite plate. Thrust force decreases as the drill tool
comes out of the CFRP composite plate after producing a hole and drops
down to zero as reaming takes place. As thrust force increases, delamination
also increases. Torque also shows similar trend except that magnitude of
variation is less as compared to that of thrust force. A proper choice of input
drilling parameters is required to decrease the thrust force and torque, so as to
minimize the delamination. The ANOVA tables are developed to find the
most influential parameter and the percentage of contributions. It is found
from the ANOVA tables calculated for all the six responses that feed rate is
the most influential factor followed by point angle. The parametric influence
on each response is studied and the interaction plots are analyzed.