Experimental Investigations into Electrochemical Spark Machining of Composites

1990 ◽  
Vol 112 (2) ◽  
pp. 194-197 ◽  
Author(s):  
V. K. Jain ◽  
S. Tandon ◽  
P. Kumar
Keyword(s):  
Cutting Tools ◽  
Tool Material ◽  
Poor Performance ◽  
Experimental Investigations ◽  
Machining Parameters ◽  
Reinforced Plastics ◽  
Kevlar Fiber ◽  
Viable Solution ◽  
Fiber Reinforced Plastics ◽  
Conventional Type

Reports have indicated the poor performance of the conventional type of cutting tools during machining of composites. In this paper electrochemical spark machining (ECSM) for the cutting and drilling of holes in the composites is being proposed. The feasibility of using ECSM for composites was first ascertained. Then, kevlar-fiber-epoxy and glass-fiber-epoxy composites as work material, copper as tool material, and an aqueous solution of NaCl as electrolyte were used. It has been concluded that the ECSM is a viable solution for cutting of Fiber Reinforced Plastics (FRP). For achieving desired accuracy, surface finish, and economics of the process, the machining parameters should be optimized.

An Investigation on Machining Power of EN-AC 48000 Aluminum Alloy Used in Automotive and Aerospace Industries

2009 ◽  
Vol 83-86 ◽  
pp. 704-710 ◽  
Author(s):  
H. Shahali ◽  
Hamid Zarepour ◽  
Esmaeil Soltani
Keyword(s):  
Signal To Noise Ratio ◽  
Cutting Tools ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Dimensional Accuracy ◽  
Machining Parameters ◽  
Anova Analysis ◽  
Essential Parameter ◽  
Cutting Velocity ◽  
Coated Carbide

In this paper, the effect of machining parameters including cutting velocity, feed rate, and tool material on machining power of EN-AC 48000 aluminium alloy has been studied. A L27 Taguchi's standard orthogonal array has been applied as experimental design to investigate the effect of the factors and their interaction. Twenty seven machining tests have been accomplished with two random repetitions, resulting in fifty four experiments. EN-AC 48000 is an important alloy in automotive and aerospace industries. Machining of this alloy is of vital importance due to build-up edge and tool wear. Machining power is an essential parameter affecting the tool life, dimensional accuracy, and cutting efficiency. Three types of cutting tools including coated carbide (CD 1810), uncoated carbide (H10), and polycrystalline diamond (CD10) have been used in this study. Statistical analysis has been employed to study the effect of factors and their interactions using ANOVA analysis. Moreover, optimal factor levels have been presented using signal to noise ratio (S/N) analysis. Also, regression model have been provided to predict the machining power. Finally, the results of confirmation tests have been presented to verify and compare the adequacy of the predictive models.

Performance of Tools Design when Helical Milling on Carbon Fiber Reinforced Plastics (CFRP) Aluminum (Al) Stack

2013 ◽  
Vol 465-466 ◽  
pp. 1075-1079 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Z. Mohid ◽  
M.R. Hamzah ◽  
A.F. Yusuf ◽  
N.A. Rahman
Keyword(s):  
Milling Process ◽  
Helical Milling ◽  
Machining Parameters ◽  
Reinforced Plastics ◽  
Comparable Performance ◽  
Hole Making ◽  
Milling Characteristics ◽  
The Common ◽  
Fiber Reinforced Plastics

Hole making process is not strictly to the drilling technique where others machining could also influence to the quality in CFRP hole.Therefore, helical milling process becomes as an alternative method to produces bore on CFRP plate thus minimizing the defects. The common defects on CFRP are delamination, splintering and cracking. Meanwhile, if the CFRP stacking together with aluminum plate, burr at exit hole of aluminium plate is produced. Therefore, it is essential to control the critical machining parameters to assure a good quality of the hole. The main objective of this project is to improve the hole quality of CFRP/AL stack in terms of surface roughness using helical milling technique. In addition the cutting force and temperature will be measured as well. There are three levels of cutting speeds; two levels of feed rate and depth per helical path are made accordingly to helical milling characteristics. It was found that all tool design exhibit comparable performance for helical milling process on CFRP/Al stack.

scholarly journals Monitoring and neural network modeling of cutting temperature during turning hard steel

2018 ◽  
Vol 22 (6 Part A) ◽  
pp. 2605-2614
Author(s):  
Mirfad Taric ◽  
Pavel Kovac ◽  
Bogdan Nedic ◽  
Dragan Rodic ◽  
Dusan Jesic
Keyword(s):  
Neural Network ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Tool Material ◽  
Cutting Parameters ◽  
Neural Network Modeling ◽  
Machining Parameters ◽  
Average Temperature ◽  
Hard Steel

In this study, cutting tools average temperature was investigated by using thermal imaging camera of FLIR E50-type. The cubic boron nitride inserts with zero and negative rake angles were taken as cutting tools and round bar of EN 90MnCrV8 hardened steel was used as the workpiece. Since the life of the cutting tool material strongly depends upon cutting temperature, it is important to predict heat generation in the tool with intelligent techniques. This paper proposes a method for the identification of cutting parameters using neural network. The model for determining the cutting temperature of hard steel, was trained and tested by using the experimental data. The test results showed that the proposed neural network model can be used successfully for machinability data selection. The effect on the cutting temperature of machining parameters and their interactions in machining were analyzed in detail and presented in this study.

An Experimental Study of the Drilling of Aramid Composites

1995 ◽  
Vol 117 (4) ◽  
pp. 271-278 ◽  
Author(s):  
F. Veniali ◽  
A. Di Ilio ◽  
V. Tagliaferri
Keyword(s):  
Feed Rate ◽  
Size Effects ◽  
Brittle Failure ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Entry And Exit ◽  
Reinforced Plastics ◽  
Cutting Energy ◽  
Fiber Reinforced Plastics ◽  
Tool Diameter

Major drilling characteristics of Aramid fiber-reinforced plastics are experimentally investigated. The chip appears highly deformed and tends to smear on the tool. Forces and, mainly, torque are more influenced by the tool diameter than by the feed rate and cutting speed. On the contrary, the specific cutting energy strongly depends upon the feed rate due to size effects of the tool tip. The damage in the work, i.e., delamination at entry and exit side, can be controlled by taking into account the relationships between machining parameters and forces and torque. Generally, the tool fails by gross brittle failure at the periphery rather than by generalized land wear.

Development of Active Laminates and Composites

Aerospace ◽  
2006 ◽  
Author(s):  
Hiroshi Asanuma
Keyword(s):  
Coefficient Of Thermal Expansion ◽  
Fiber Type ◽  
Fiber Direction ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Fiber Layer ◽  
Reinforced Plastics ◽  
Kevlar Fiber ◽  
Discontinuous Fiber ◽  
Fiber Reinforced Plastics

The present paper describes development of active laminates and composites proposed by Asanuma. The active laminates were successfully made by hot-pressing of an aluminum plate as a high CTE (Coefficient of Thermal Expansion) material, a unidirectional CFRP (Carbon Fiber Reinforced Plastics) prepreg as a low CTE material and an electric resistance heater, and a KFRP (Kevlar Fiber Reinforced Plastics) prepreg as a low CTE material and an insulator between them. Curvature of the active laminate linearly changes only in the fiber direction as a function of temperature, and it was made into complicated forms and their actuation performances were successfully demonstrated. As a high temperature type active laminate, three types of SiC/Al composites, that is, a laminate of continuous-fiber layer and unreinforced one, that of discontinuous-fiber layer and unreinforced one, and that of continuous-fiber layer and discontinuous-fiber one were fabricated, and it became clear that all of the composites curve unidirectionally in the fiber direction, and the curvatures reproducibly change during thermal cycles between room temperature and 813 K. Tensile strength of the combination type is higher than that of the continuous-fiber type, and its curvature exists between the continuous-fiber type and the discontinuous-fiber type.

A Study of Cutting Temperatures in Turning Carbon-Fiber-Reinforced -Plastics (CFRP) Composites with Sharp Worn Tools

2011 ◽  
Vol 233-235 ◽  
pp. 2790-2793
Author(s):  
Chung Shin Chang ◽  
Yuh Ming Chang
Keyword(s):  
Carbon Fiber ◽  
Cutting Tools ◽  
Heat Transfer Analysis ◽  
Fiber Reinforced ◽  
Element Analysis ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Cfrp Composites ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

Temperatures of the carbide tip's surface when turning Carbon-Fiber-Reinforced Plastics (CFRP) composites with a sharp worn main cutting edge tool is investigated. The frictional forces and heat generated in the basic cutting tools are calculated by using the measured cutting forces and the theoretical cutting analysis. The heat partition factor between the tip and chip is solved by using the inverse heat transfer analysis, which utilizes temperature on the carbide tip’s surface measured by infrared as the input. The tip’s surface temperature is determined by finite element analysis (FEA) and compared with temperatures obtained from experimental measurements. Good agreement demonstrates the accuracy of the proposed model.

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