High Speed Routing of Woven Carbon Fiber Reinforced Epoxy Laminates

2012 ◽  
Author(s):  
M. Meshreki ◽  
A. Sadek ◽  
M. H. Attia
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Tool Wear ◽  
High Speed ◽  
Thermal Characteristics ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Axial Forces ◽  
Carbon Fiber Reinforced ◽  
Dimensional Errors

Little is known about the high speed routing of Carbon Fiber Reinforced Polymers (CFRP). Most of the work in the literature has focused on the drilling of CFRP. In this paper, an extensive experimental study has been conducted to better understand the dynamic, tribological, and thermal characteristics of high speed milling of CFRPs, in the range of 10,000 to 40,000 rpm (200 to 800 m/min, for 6.35 mm end-mill). The material used was a quasi-isotropic laminate comprising 35 plies of woven graphite epoxy. The tool wear was investigated on the flank and the rake faces. The machined slots were characterized in terms of straightness errors, dimensional errors, surface roughness, and delamination. The tool over-hang controls the tool dynamics, in this high speed range, and significantly affect various quality attributes of the produced holes; roughness, dimensional errors, and straightness. Similar trends were observed for the forces and the temperatures, whereby there is a given speed at which they reach a minimum and then they start to increase for higher speeds. The machining force and temperature trends with varying speeds and feeds are controlled by the chip load, the specific cutting pressures, and the effect of the frictional forces. The increased tool wear was found to directly affect the cutting forces and consequently lead to high delamination and surface roughness. The milled surface quality was mainly controlled by the feed rate. Limited surface delamination was observed due to the low axial forces associated with the routing process.

CRYOGENIC DRILLING OF CARBON FIBER-REINFORCED COMPOSITE (CFRP)

2019 ◽  
Vol 26 (09) ◽  
pp. 1950060 ◽  
Author(s):  
UĞUR KOKLU ◽  
SEZER MORKAVUK
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Tool Wear ◽  
Thrust Force ◽  
Fiber Reinforced Polymers ◽  
Cryogenic Machining ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Polymers ◽  
Reinforced Polymers ◽  
Carbon Fiber Reinforced

In order to reduce the adverse effects on the environment and economy and to avoid health problems caused by the excessively used cutting lubrications, cryogenic machining is drawing more and more attention. In this work, a novel cryogenic machining approach was applied for drilling of carbon fiber-reinforced polymers (CFRPs). According to this approach, CFRP was dipped into the liquid nitrogen (LN2) and it was machined within the cryogenic coolant directly. Various machinability characteristics on thrust force, delamination damage, tool wear, surface roughness, and topography were compared with those obtained with dry condition. This experimental study revealed that the novel method of machining with cryogenic dipping significantly reduced tool wear and surface roughness but increased thrust force. Overall results showed that the cryogenic machining approach in this study improved the machinability of CFRP.

EB-Irradiation Induced Strengthening of Carbon Fiber Reinforced Thermoplastic Polymers

2014 ◽  
Vol 922 ◽  
pp. 838-843
Author(s):  
Yoshiki Yamazaki ◽  
Hiroaki Takei ◽  
Masae Kanda ◽  
Keisuke Iwata ◽  
Michelle Salvia ◽  
...  
Keyword(s):  
Electron Beam ◽  
Carbon Fiber ◽  
High Speed ◽  
Fracture Strain ◽  
High Energy ◽  
Bending Test ◽  
Fiber Reinforced Polymers ◽  
Resin Matrix ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced

Carbon fiber reinforced polymers (CFRP), which are typical composite materials, and have been applied as light structural materials with high strength [1, 2]. The further strengthening has been always expected to develop high speed transports with small energy consumption. Although influences of electron beam (EB) irradiation with high energy on the fracture toughness of carbon cross of carbon fibers in thermo-hardened epoxy resin matrix (thermo-hardened CFRP) have been often reported [3], no one has succeeded the strengthening of CFRP irradiated by electron beam. On the other hand, the homogeneous low voltage electron beam irradiation (HLEBI) often induces not only the hardening, high wear resistance and sterilization for practical use of polymer, but also the mist resistance [4–6]. In addition, the irradiation has improved not only the bending fracture strain of carbon fiber [7, 8], but also the deformation resistivity, strength and fracture strain on static tensile test [9]. In our recent research, it has succeeded that the EB-irradiation also enhances the fracture stress and fracture strain of static bending test of thermo-hardened CFRP [10]. Furthermore, the improvement of impact value of thermo-hardened CFRP by EB-irradiation has been also reported to apply to high-speed transports [11]. However, the production rate of thermo-hardened CFRP has been serious problem in mass production.

scholarly journals Effect of Tool Wear on Quality of Carbon Fiber Reinforced Polymer Laminate during Edge Trimming

2013 ◽  
Vol 325-326 ◽  
pp. 34-39 ◽  
Author(s):  
Hossein Hamedanianpour ◽  
Jean François Chatelain
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Tool Wear ◽  
Matrix Cracking ◽  
Fiber Reinforced ◽  
Pull Out ◽  
Carbon Fiber Reinforced ◽  
Coated Carbide ◽  
Cutting Speeds

Polymer matrix composites, particularly carbon fiber reinforced polymers (CFRPs) are widely used in various high technology industries, including aerospace, automotive and wind energy. Normally, when CFRPs are cured to near net shape, finishing operations such as trimming, milling or drilling are used to remove excess materials. The quality of these finishing operations is highly crucial at the level of final assembly. The present research aims to study the effect of cutting tool wear on the resulting quality for the trimming process of high performance CFRP laminates, in the aerospace field. In terms of quality parameters, the study focuses on surface roughness and material integrity (uncut fibers, fiber pull-out, delamination or thermal damage of the matrix), which could jeopardize the mechanical performance of the components. In this study, a 3/8 inch diameter CVD diamond coated carbide tool with six straight flutes was used to trim 24-ply carbon fiber laminates. Cutting speeds ranging from 200 m/min to 400 m/min and feed rates ranging from 1524 mm/min to 4064 mm/min were used in the experiments. The results obtained using a scanning electron microscope (SEM) showed increasing defect rates with increased tool wear. The worst surface integrity, including matrix cracking, fiber pull-out and empty holes, was also observed for plies oriented at -45 degrees. For the surface finish, it was observed that for the studied cutting length ranges, an increase in tool wear resulted in a decrease in surface roughness. Regarding tool wear, a lower rate was observed at lower feed rates and higher cutting speeds, while a higher tool wear rate was observed at intermediate values of our feed rate and cutting speed ranges.

A comparative study on tool wear and laminate damage in drilling of carbon-fiber reinforced polymers (CFRP)

2016 ◽  
Vol 155 ◽  
pp. 173-183 ◽  
Author(s):  
Simon Gaugel ◽  
Prithvi Sripathy ◽  
Andreas Haeger ◽  
Dieter Meinhard ◽  
Timo Bernthaler ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Tool Wear ◽  
Comparative Study ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Polymers ◽  
Reinforced Polymers ◽  
Carbon Fiber Reinforced

Accuracy and surface quality of abrasive waterjet machined CFRP composites

2020 ◽  
pp. 002199832097442
Author(s):  
HA Youssef ◽  
HA El-Hofy ◽  
AM Abdelaziz ◽  
MH El-Hofy
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Removal Rate ◽  
Kerf Width ◽  
Fiber Reinforced Polymers ◽  
Abrasive Waterjet ◽  
Experimental Investigations ◽  
Fiber Reinforced ◽  
Cfrp Laminates ◽  
Carbon Fiber Reinforced

The use of carbon fiber-reinforced composites is increasing today since they have an excellent weight-to-mechanical properties ratio. Traditional machining of this material is difficult. Abrasive water jet machining (AWJM) is an advanced non-traditional material removal process that can machine hard-to-cut materials. The process is widely used in aerospace, marine, and automotive industries. However, it encounters several challenges when cutting carbon fiber reinforced polymers (CFRP). The present work aims to study the characteristics of AWJM of CFRP laminates. Detailed experimental investigations are conducted to explore the effect of traverse feed and standoff distance (SOD) on top kerf width, bottom kerf width, kerf angle, profile area, volumetric removal rate, and the average surface roughness, and jet deviation factor. Repeatability tests are also used to assess the kerf dimensional accuracy and surface roughness tolerance achieved by AWJM of CFRP laminates. Results showed that the surface roughness increases along with the cut thickness, especially at large traverse feed and SOD. Both the kerf taper angle and the volumetric removal rate increase with traverse feed and SOD.

Machinability of Fiber-Reinforced Thermoplastics in Drilling

1993 ◽  
Vol 115 (1) ◽  
pp. 146-149 ◽  
Author(s):  
H. Hocheng ◽  
H. Y. Puw
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Fiber Reinforced ◽  
Heat Accumulation ◽  
Edge Quality ◽  
Carbon Fiber Reinforced

Polymer-based composite materials are used in a variety of industry. Recently, thermoplastic polymer suitable for the resinous matrix in carbon fiber-reinforced composites has been introduced for lower material and processing costs, improved damage tolerance and higher moisture resistance. The successful use of this material requires sophisticated production technology, however little reference of machining of thermoplastics composites can be found. The existing published results are almost exclusively for epoxy-based composite materials showing difficulty in avoiding poor finish, serious tool wear and delamination at hole entrance and exit due to the brittle material response to machining. Thermoplastics-based composite materials possesses better machinability. The current work reveals the machinability of an example of carbon fiber-reinforced ABS (Acrylonitrile Butadiene Styrene) in drilling compared to representative metals and thermoset-based composites. The observation of chips reveals that considerable plastic deformation is involved. Compared to the chip formation of thermoset plastics, it contributes to the improved edge quality in drilling. The edge quality is generally fine except in the case of concentrated heat accumulation at tool lips, which is generated by high cutting speed and low feed rate. Plastics tend to be extruded out of the edge rather than neatly cut. The average surface roughness along hole walls in commonly below one micron for all sets of cutting conditions in the experiment, values between 0.3 and 0.6 microns are typical. The high speed steel drill presents only minor tool wear during the tests. Based on these results, one concludes that the carbon fiber-reinforced ABS demonstrates good machinability in drilling.

Experimental Study on Temperature Effect and Tool Wear on Edge Trimming of Carbon Fiber Reinforced Plastics

2014 ◽  
Vol 592-594 ◽  
pp. 333-338 ◽  
Author(s):  
R. Prakash ◽  
V. Krishnaraj ◽  
G.S. Tarun ◽  
M. Vijayagopal ◽  
G.Denesh Kumar
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Tool Wear ◽  
Weight Ratio ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced ◽  
Edge Trimming

Carbon fiber reinforced plastics (CFRP) are used as structural materials in automotive and aerospace industries because of its superior properties like high strength to weight ratio and high stiffness to weight ratio. Though most CFRP products are produced to near net shape by different composite manufacturing methods, some post machining processes such as drilling, edge trimming are required. In order to shape and smooth the edges of the composite components the edge trimming plays a major role. This research gave the approach of studying the effect of temperature and tool wear on surface roughness obtained during edge trimming of uni directional CFRP with different fiber orientations and quasi isotropic CFRP with the sequence of [90/-45/0/45/90/-45/0/45]S.The effect of coating of tool on tool wear and surface roughness were also studied.

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