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.

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.

Surface Roughness in Drilled Carbon Fiber Reinforced Polymer (CFRP) Composite Using Diamond Coated Ball-Nose Drills

2015 ◽  
Vol 1115 ◽  
pp. 90-95 ◽  
Author(s):  
Mohamed Konneh ◽  
Sudin Izman ◽  
Atiah Abdullah Sidek ◽  
Muhammad Salahuddin Salleh
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Feed Rate ◽  
Rotational Speed ◽  
Machining Parameters ◽  
Fiber Reinforced ◽  
Cfrp Composite ◽  
Carbon Fiber Reinforced ◽  
Coated Carbide ◽  
Twist Drills

This paper discusses an experimental investigation into the influence of machining parameters on surface roughness when drilling CFRP using 4 mm-diameter 2-fluted carbide drills coated with diamond. The experimental plan employed in this study is based on Central Composite Design technique, established considering drilling with prefixed cutting parameters in a locally prepared Carbon Fiber-Reinforced Plastic (CFRP) composite material by hand lay-up technique using diamond coated carbide twist drills. A model using multiple regression analysis between rotational speed and feed rate with the surface roughness (Ra) of the fiber reinforced laminates has been predicted for the machining conditions investigated. It has been found that the lowest surface roughness Ra (0.910 μm) was generated at rotational speed, 5062 rpm and feed rate, 180 mm/min; and the highest surface roughness Ra (4.630 μm) generated at a rotational speed of 537 rpm and feed rate of 180 mm/min.

scholarly journals Effects of the Longitudinal Surface Roughness on Fiber Pull-Out Behavior in Carbon Fiber-Reinforced Epoxy Resin Composites

2013 ◽  
Vol 80 (2) ◽  
Author(s):  
Yin Yao ◽  
Shaohua Chen
Keyword(s):  
Surface Roughness ◽  
Theoretical Model ◽  
Carbon Fiber ◽  
Aspect Ratio ◽  
Epoxy Resin ◽  
Carbon Fibers ◽  
Fiber Reinforced ◽  
Fiber Stress ◽  
Pull Out ◽  
Carbon Fiber Reinforced

Surface modifications are known as efficient technologies for advanced carbon fibers to achieve significant improvement of interface adhesion in composites, one of which is to increase the surface roughness in the fiber's longitudinal direction in practice. As a result, many microridges and grooves are produced on carbon fiber's surfaces. How does the surface roughness influence the carbon fiber's pull-out behavior? Are there any restrictions on the relation between the aspect ratio and surface roughness of fibers in order to obtain an optimal interface? Considering the real morphology on carbon fiber's surface, i.e., longitudinal roughness, an improved shear-lag theoretical model is developed in this paper in order to investigate the interface characteristics and fiber pull-out for carbon fiber-reinforced thermosetting epoxy resin (brittle) composites. Closed-form solutions to the carbon fiber stress are obtained as well as the analytical load-displacement relation during pullout, and the apparent interfacial shear strength (IFSS). It is found that the interfacial adhesion and the apparent IFSS are effectively strengthened and improved due to the surface roughness of carbon fibers. Under a given tensile load, an increasing roughness will result in a decreasing fiber stress in the debonded zone and a decreasing debonded length. Furthermore, it is interesting to find that, for a determined surface roughness, an optimal aspect ratio, about 30∼45, of carbon fibers exists, at which the apparent IFSS could achieve the maximum. Comparison to the existing experiments shows that the theoretical model is feasible and reasonable to predict the experimental results, and the theoretical results should have an instructive significance for practical designs of carbon/epoxy composites.

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.

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.

Qualitätssteigerung von Bohrungen in Faserkunststoffverbunden*/Increased quality of bores in fiber reinforced polymers

2015 ◽  
Vol 105 (07-08) ◽  
pp. 501-507
Author(s):  
L. Heberger ◽  
S. Nissle ◽  
M. Gurka ◽  
B. Kirsch ◽  
J. C. Aurich
Keyword(s):  
Carbon Fiber ◽  
Computer Tomography ◽  
Drill Hole ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Hole Quality ◽  
Carbon Fiber Reinforced Polymers ◽  
Reinforced Polymers ◽  
Carbon Fiber Reinforced

Beim Bohren von kohlefaserverstärktem Kunststoff treten verstärkt Schädigungen wie Delaminationen und Faserüberstände auf. Mit dem Ziel die Bohrlochqualität zu verbessern, wurde der Einfluss der Werkstückeinspannung hinsichtlich Einspanngeometrie, -kraft und -material untersucht. Zusätzlich zur konventionellen optischen Delaminationsmessung wurde die äußere und die innere Delamination mittels Mikrocomputertomografie analysiert. Durch eine Optimierung der Einspannung konnte die Bohrlochqualität gesteigert werden.   When drilling carbon fiber reinforced polymers damages like delamination and fiber protrusion appear. Aiming to improve the drill hole quality, the influence of the fastening device with respect to fastening geometry, force and material is analyzed. In addition to the conventional optical delamination measurement, the outer and inner delamination is investigated by micro computer tomography. The optimization of the fastening device leads to a higher drill hole quality.

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