Madan Mohan Malaviya Univ.

of Technology, Gorakhpur
A Minor Project
on
NUMERICAL SIMULATION OF LASER DRILLING PROCESS IN
CFRP COMPOSITE
By
Awadhesh
(M.Tech-CIM, 2020053107)

under the supervision of

Dr. Sanjay Mishra

Department of Mechanical Engineering

Email: [email protected]

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CONTENTS
 Introduction

 Benefits of Laser Drilling .

 Research Gap

 Objective

 Machining Process

 Methodology

 Steps of Numerical Analysis used in laser drilling

 Work status

 References

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Introduction
• Perhaps the biggest advantage of composites is their high strength-to-weight ratio. Carbon
fiber weighs about 25% as much as steel and 70% as much as aluminum, and is much stronger
and stiffer than both materials per weight.

• Composites never rust, regardless of their environment (though they are prone to corrosion
when bonded to metal parts). Composites have less fracture toughness than metals but more
than most polymers.

• Non-conventional process promoted longer tool life because no direct contact is made between
the tool and the materials. Tools used in non-conventional processes are more accurate and
with higher precision compared to conventional tools that create conventional parts.

• The traditional machining processes rely on harder tool or abrasive material to remove the
softer material whereas non-traditional machining processes such as EDM uses electrical spark
or thermal energy to erode unwanted material in order to create desired shape.

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Conventional Machining challenges in CFRP

• With the growing use of polymer composites in aerospace, naval, industrial, electronics and other
industries, the effective machining of these composites is becoming highly significant.

• The use of conventional machining methods such as turning, milling, drilling, shaping etc.
Damages the polymer composites due to its inherent heterogeneity.

• Matrix cracking, fiber pullouts, fuzzing, delamination, tool wear, thermal degradation, excessive
dust generation etc, are some of the common problems associated with conventional machining of
polymer composite.

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Benefits of Laser Drilling

•Reasonable improvements in drilling quality is achieved by using pulsed Nd:YAG laser. It provides
high beam intensity, less interaction time, better focusing behavior and smaller HAZ.

•Because of its key advantages such as high operating speed, high flexibility, and high machining
rate , with higher accuracy, repeatability, and reproducibility.

• laser is widely used in many industries like heavy machinery, aerospace , marine , chemical and
automotive industries.

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Research Gap
• Most of the experimental work has been done on metal and alloy by conventional drilling.

• Non conventional drilling like AJD, ECD etc. are used to metal and alloy.

• Very few literature are available on FRP based material by laser drilling techniques.

• Numerical analysis through hole in FRP material by ANSYS are rarely in literature.

• Very few literature are available on Numerical Simulation of CFRP composite by laser drilling
process based on thickness.

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Objective

Numerical Simulation of Laser Drilling Process in CFRP Composite

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Machining Process

• Neodymium-doped Yttrium Aluminium Garnet (Nd: YAG) laser is a solid

• These lasers operate in both pulsed and continuous mode. Nd: YAG laser
generates laser light commonly in the near-infrared region of the spectrum at
1064 nanometres (nm).

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[physicswave.com]
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Methodology
• Ansys engineering simulation and 3D design software delivers product modeling
solutions with unmatched scalability and a comprehensive multiphasic.
• In present study, temperature and thermal stress distribution have been predicted on
selected parameters (power and cutting speed) for through-hole formation on
CFRP Composite during Nd:YAG laser drilling. Finite element software (ANSYS)
has been used to simulate the problem and found predicted selected responses are
suitable for laser drilling.
• ANSYS is a large common finite element analysis software gathered with
structural, thermal, fluid, electromagnetic, acoustics in which is widely used in
mechanical manufacturing, aerospace, electronics, civil engineering, water,
petrochemical, light industry and many industrial areas. It can solve the problems
of steady state, transient, linear and nonlinear heat conduction.
• The used analysis was "transient analysis". The concept of "Moving heat source"
and "element birth & death model" technique in ANSYS.

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MATREIAL PROPERTIES
• Carbon fiber-reinforced carbon (C/C) composites consist in a carbon matrix, which holds
carbon or graphite fibers together. Their physical properties are determined by the fibers,
matrix materials, layer buildup, as well as the material preparation and processing.
• They are designed as materials of high performance for highly demanding applications,
looking for low thermal expansion, low density, high resistance to thermal shock, very
good creep resistance at elevated temperatures, good chemical stability, among others.
• In this work, we use Laser Flash Technique to study the thermal diffusivity and thermal
conductivity of carbon fiber-reinforced carbon (C/C) composite consisting in laminates
of weaved bundles of carbon fibers, forming a regular and repeated orthogonal pattern,
all of them built into a matrix of graphite.
Material Thermal Thermal Density (w/mk) Tensile strength (N/m2)
conductivity (w/mk) diffusivity (m2/sec)
Carbon 50 0.000750 2250 4300
Epoxy 0.294 1900 30

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Steps of Numerical Analysis used in laser drilling

CFRP Composite Simulation in ANSYS Workbench→ ACP

2).ACP (Pre) > Geometry > Units >X Y Plane (Axis)>Rectangle >30 x 30 (mm) > End
sketching> close.

3)ACP (Pre) > modal > thickness > 3mm.

4)ACP (Pre) > model> mesh > Generate mesh > close.

5)ACP(Pre) > Setup > ACP model > materials Data>materials > select martials (update to
click right).

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(Firstly check units)

6)Materials Data > Fabrics (right click and create Fabrics > Change Name> Select the
material > Give thickness .
(If want to see material properties then clock Analysis and right trick in E1, E2, E3 and Apply and
show Polar diagram of material and click ok )

7)Material data> stackups > right click and Create stackups1 and click > chose fabric.
(If want to give angle then give angle otherwise leave it)
(Choose multiple fabric layer according to your thickness of components for composite ) ok
(f want to see polar properties then select Analysis)

After all process then click on stackups 1 and update.

8)ACP modal > Elements Sets > All elements > update.

9)ACP model> Rosettes > Rosettes(or global co-ordinate system)> update .

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10)ACP model > Rosettes> right click and create Rosettes>Origin: (26.1954,5-7621, 0.0000)
Direction 1: (1.0000,0.0000,0.0000)
Direction 2: (0.0000, 1.0000, 0.0000)
>Apply > ok.
11)ACP Modal> Oriented Selection Sets > right click and Create Oriented Selection set
>Element Sets >
(clock on All-Elements in [] and see [All Elements]) > click the orientation points (26.1554,
5.7627,000)
>Orientations Direction (0.0000, 0.0000, 1.080)>Rosettes: [] click on Rosette. 1 (to see
[Rosette.1]] >ok and update.
12) ACP modal > modeling. Groups > right click and Create modeling Group… > ok
13)Modelling Groups > modelling Group.1 > right click and create Ply….> Oriented
Selection Sets [] (click on ‘Oriented selection set.1, after click see[ Oriented selection
set.1]>Ply material: > Stackup.1 > ok and update.

14)ACP model) Solid Models > right clock “Create Modelling -Croup… >Element Sets: []
click on All- Elements >OK>update.

15) close Program> update.

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Process of leaser drilling:-

Project (ACP(Pre) > Transient Thermal).

Model > Geometry > Solid model.1.

Model >materials > Graphite and FR-4 Epoxy.

model > mesh > Mesh Edit> Mode Move > Named selections.

model > Transient Thermal > Initial temperature Analysis settings > Temperature>
Element Birth and Death.

model > Solution > Solution information >temperature

model > solution >total Heat flux

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Input parameter:-

Temperature (by using Heat flux, radial location, pulse width time, thermal
diffusivity and thermal conductivity.
Heat flux=5.5499*10

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Work status

• The temperature analysis of composite material CFRP have been done in ANSYS.

• Reaming Analysis which is to find heat flux of composite material CFRP on progress.

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RESULT AND CONCLUSION

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FUTUURE SCOPE

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References
• https://www.mm.bme.hu/~gyebro/files/vem/ansys_13_command_reference.pdf

• https://www.researchgate.net/publication/
314305064_Verifying_the_Effect_of_Element_Birth_and_Death_Technique_on_Stress_Distribution_in_Cracked
_Areas

• https://www.sv-jme.eu/?ns_articles_pdf=/ns_articles/files/ojs/1897/public/1897-12002-1-PB.pdf&id=3170

• https://www.tandfonline.com/doi/abs/10.1179/1743284714Y.0000000703?journalCode=ymst20

• https://www.mdpi.com/2079-6412/8/10/336

• https://www.sciencedirect.com/science/article/abs/pii/S0142112319302440

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Thanking
You

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