Machinability and Ergonomic Assessment during Processing of Composite Materials
Sr. Gr. Lecturer, Department of Mechanical Engineering, Smt. L. V. Government Polytechnic, Hassan – 573201 Karnataka India.
Lecturer, Department of Mechanical Engineering, Government Polytechnic, Holenarasipura- 573211, Karnataka India.
Research Article
World Journal of Advanced Research and Reviews, 2022, 15(01), 870-876
Publication history:
Received on 11 July 2022; revised on 17 July 2022; accepted on 28 July 2022
Abstract:
The widespread adoption of composite materials across diverse industries—such as aerospace, automotive, marine, and energy—has brought forth both remarkable opportunities and unique challenges in manufacturing. As composites continue to replace traditional materials due to their exceptional strength-to-weight ratio, corrosion resistance, and design flexibility, optimizing their processing has become increasingly critical. Central to this optimization is a deep understanding of two interrelated factors: machinability and ergonomics. Machinability encompasses the ease with which composite materials can be cut, shaped, and finished, directly impacting tool wear, surface finish quality, and material removal rates. Factors such as fiber orientation, matrix composition, and the abrasive nature of composites intensify concerns around tool life and process efficiency, often necessitating specialized tooling and machining techniques. Simultaneously, the shift towards greater composite utilization brings new ergonomic considerations to the fore. Operators involved in composite processing are exposed to distinct physical and environmental risks, including dust generation, repetitive movements, awkward postures, and vibration, all of which can affect health, comfort, and productivity. Addressing these ergonomic challenges is essential for fostering a safe and sustainable workplace, minimizing injury risks, and supporting long-term operational effectiveness. This paper provides a comprehensive investigation into the machinability of composite materials, focusing on critical issues such as tool wear mechanisms, surface integrity, and the optimization of material removal rates. Alongside these technical aspects, the research assesses prevailing ergonomic risks and strategies for mitigating their impact on workers. By critically reviewing recent literature and examining current industrial practices, the study highlights both the persistent challenges—such as rapid tool degradation and insufficient ergonomic interventions—and the progress made through technological advances and integrated assessment approaches. A key proposition of this work is the integration of machinability and ergonomic assessments as a holistic strategy for achieving both operational efficiency and worker safety. Rather than treating these domains in isolation, the paper argues for their concurrent evaluation, which can lead to synergistic improvements in process design, equipment selection, and workplace layout. Finally, the study outlines recommendations for future research, calling for the development of standardized assessment tools, enhanced simulation and modeling techniques, and cross-disciplinary collaboration. It also suggests practical steps for industry, such as investing in automation, adopting advanced monitoring systems, and prioritizing ergonomic training. Collectively, these recommendations aim to advance both the science and practice of composite material processing in a direction that is efficient, competitive, and human-centered.
Keywords:
Machinability; Composite Materials; Ergonomics; Manufacturing; Tool Wear; Surface Finish; Operator Health
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