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

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A Study on the Laser-Assisted Machining of Carbon Fiber Reinforced Silicon Carbide

Materials ◽

10.3390/ma12132061 ◽

2019 ◽

Vol 12 (13) ◽

pp. 2061 ◽

Cited By ~ 5

Author(s):

Khulan Erdenechimeg ◽

Ho-In Jeong ◽

Choon-Man Lee

Keyword(s):

Surface Roughness ◽

Silicon Carbide ◽

Carbon Fiber ◽

Cutting Force ◽

Ceramic Composites ◽

Depth Of Cut ◽

Machining Parameters ◽

Fiber Reinforced ◽

Laser Assisted Machining ◽

Carbon Fiber Reinforced

In recent years, as replacements for traditional manufacturing materials, monolithic ceramics and carbon fiber reinforced silicon carbide (C/SiC) ceramic matrix composites have seen significantly increased usage due to their superior characteristics of relatively low density, lightweight, and good high temperature mechanical properties. Demand for difficult-to-cut materials is increasing in a variety of area such as the automotive and aerospace industries, but these materials are inherently difficult to process because of their high hardness and brittleness. When difficult-to-cut materials are processed by conventional machining, tool life and quality are reduced due to the high cutting force and temperatures. Laser-assisted machining (LAM) is a method of cutting a workpiece by preheating with a laser heat source and lowering the strength of the material. LAM has been studied by many researchers, but studies on LAM of carbon–ceramic composites have been carried out by only a few researchers. This paper focuses on deducing the optimal machining parameters in the LAM of C/SiC. In this study, the Taguchi method is used to obtain the major parameters for the analysis of cutting force and surface roughness under various machining conditions. Before machining experiments, finite element analysis is performed to determine the effective depth of the cut. The cutting parameters for the LAM operation are the depth of cut, preheating temperature, feed rate, and spindle speed. The signal to noise (S/N) ratio and variance analysis (ANOVA) of the cutting force and surface roughness are analyzed, and the response optimization method is used to suggest the optimal machining parameters.

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

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.325-326.34 ◽

2013 ◽

Vol 325-326 ◽

pp. 34-39 ◽

Cited By ~ 8

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.

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