Influence of Fiber Orientation on Machined Surface Quality in Milling of Unidirectional CFRP Laminates

2016 ◽  
Vol 1136 ◽  
pp. 137-142 ◽  
Author(s):  
Chang Ying Wang ◽  
Liang Wen ◽  
Cheng Dong Wang ◽  
Hong Zhou Zhang ◽  
Qing Long An ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Surface Quality ◽  
Fiber Orientation ◽  
Orientation Angle ◽  
Machined Surface ◽  
Cfrp Laminates ◽  
Pull Out ◽  
Machined Surface Quality ◽  
Fiber Orientation Angle

Machined surface quality is the deciding factor when evaluating the machinability of CFRP. This present work concerns the influence of fiber orientation on the machined surface quality of the machined surface in terms of surface morphology and surface roughness during milling of unidirectional T800/X850 CFRP laminates. Four group milling tests are conducted under the fiber orientation angle of 0°, 45°, 90° and 135°, respectively. For the fiber orientation angle of 0°, the machined defects are mainly fiber pull-out and fiber brittle fracture owing to interfacial debonding between the fibers and matrix resin. For the fiber orientation angle of 45°, the machined defects are mainly resin cavities and the surface morphology is rough and presents wavy fractures. For the fiber orientation angle of 90°, smooth or neat surface is observed except for the surface as the cutting tool cutting in the workpiece on which severe cracks are observed. For the fiber orientation angle of 135°, the surface is smooth with less fibers pull-out. Evaluation profile and surface roughness of the machined surfaces were measured as well. Dramatically fluctuate of the evaluation profile is observed for the fiber orientation angle of 45° with a high surface roughness Ra. Verification tests were also conducted on the multidirectional CFRP (cross-ply) laminates. It is indicated that the presence of the fiber orientation angle of 45° is the main factor leading to the decline of the machined surface quality.

Evaluation of DPI Change Impact on Laser Machined Surface Quality

2014 ◽  
Vol 474 ◽  
pp. 369-374
Author(s):  
Jana Knedlova ◽  
Libuše Sýkorová ◽  
Vladimír Pata ◽  
Martina Malachová
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Laser Micromachining ◽  
Technological Parameters ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Machined Surface Roughness ◽  
Change Impact

The article focuses on the field of PMMA laser micromachining at change of the technological parameters. The aim was to evaluate machined surface roughness at different setting of DPI definition (number of dots paths on square inch). Commercial CO2laser Mercury L-30 by firm LaserPro, USA was used for experimental machining. Ray of laser could be focused on mark diameter d=185 mm.

scholarly journals Surface Roughness Analysis of H13 Steel during Electrical Discharge Machining Process Using Cu–TiC Sintered Electrode

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 5943
Author(s):  
Arminder Singh Walia ◽  
Vineet Srivastava ◽  
Mayank Garg ◽  
Nalin Somani ◽  
Nitin Kumar Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
H13 Steel ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Semi Empirical

In electrical discharge machining (EDM), the machined surface quality can be affected by the excessive temperature generation during the machining process. To achieve a longer life of the finished part, the machined surface quality plays a key role in maintaining its overall integrity. Surface roughness is an important quality evaluation of a material’s surface that has considerable influence on mechanical performance of the material. Herein, a sintered cermet tooltip with 75% copper and 25% titanium carbide was used as tool electrode for processing H13 steel. The experiments have been performed to investigate the effects of EDM parameters on the machined surface roughness. The findings show that, as the pulse current, pulse length, and pulse interval are increased, the surface roughness tends to rise. The most significant determinant for surface roughness was found to be pulse current. A semi-empirical surface roughness model was created using the characteristics of the EDM technique. Buckingham’s theorem was used to develop a semi-empirical surface roughness prediction model. The semi-empirical model’s predictions were in good agreement with the experimental studies, and the built empirical model based on physical features of the cermet tooltip was tested using dimensional analysis.

scholarly journals Experimental Optimization of Annular Polishing Parameters for Silicon Carbide

2018 ◽  
Vol 2018 ◽  
pp. 1-6
Author(s):  
Yuan Liu ◽  
La Han ◽  
Haiying Liu ◽  
Yikai Shi ◽  
Junjie Zhang
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Surface Quality ◽  
Material Removal ◽  
Polished Surface ◽  
Strong Impact ◽  
Machined Surface ◽  
Experimental Optimization ◽  
Machined Surface Quality ◽  
Influential Parameters

Machined surface quality has a strong impact on the functionality of silicon carbide-based components and devices. In the present work, we first analytically investigate the complex coupling of motions in annular polishing based on the Preston equation, which derives the influential parameters for material removal. Subsequently, we conduct systematic annular polishing experiments of reaction-bonded silicon carbide to investigate the influence of derived parameters on polished surface quality, which yield optimized polishing parameters for achieving ultralow surface roughness of reaction-bonded silicon carbide.

scholarly journals On the Effect of Electron Beam Melted Ti6Al4V Part Orientations during Milling

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1172
Author(s):  
Abdulmajeed Dabwan ◽  
Saqib Anwar ◽  
Ali M. Al-Samhan ◽  
Mustafa M. Nasr
Keyword(s):  
Surface Roughness ◽  
Electron Beam ◽  
Surface Morphology ◽  
Surface Quality ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Radial Depth

The machining of the electron beam melting (EBM) produced parts is a challenging task because, upon machining, different part orientations (EBM layers’ orientations) produce different surface quality even when the same machining parameters are employed. In this paper, the EBM fabricated parts are machined in three possible orientations with regard to the tool feed direction, where the three orientations are “tool movement in a layer plane” (TILP), “tool movement perpendicular to layer planes” (TLP), and “tool movement parallel to layers planes” (TPLP). The influence of the feed rate, radial depth of cut, and cutting speed is studied on surface roughness, cutting force, micro-hardness, microstructure, chip morphology, and surface morphology of Ti6Al4V, while considering the EBM part orientations. It was found that different orientations have different effects on the machined surface during milling. The results show that the EBM parts can achieve good surface quality and surface integrity when milled along the TLP orientation. For instance, surface roughness (Sa) can be improved up to 29% when the milling tool is fed along the TLP orientation compared to the other orientations (TILP and TPLP). Furthermore, surface morphology significantly improves with lower micro-pits, redeposited chips, and feed marks in case of the TLP orientation.

Study on Surface Roughness Simulation to Lathe Machining

2012 ◽  
Vol 538-541 ◽  
pp. 1373-1376
Author(s):  
Dong Xie ◽  
Min Wang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Material ◽  
Cutting Parameters ◽  
Simulation System ◽  
Cnc Machining ◽  
Machined Surface ◽  
Cutting Surface ◽  
Machined Surface Quality ◽  
The Mathematical Model

This paper presents a simulation system for the cutting surface roughness based on the feed rate, spindle speed and tool material, shape and other parameters. The reasons affecting the surface quality in machining is explained. Using classic formula and empirical data, the mathematical model of the surface roughness is built to predict surface quality of parts. The paper proposes a method of the simulation system design for the machined surface quality. The simulation results could give a guide to the choice of cutting parameters in CNC machining.

scholarly journals Influence of Lubricant Environment on Machined Surface Quality in Single-Point Diamond Turning of Ferrous Metal

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1110
Author(s):  
Menghua Zhou ◽  
Jianpeng Wang ◽  
Guoqing Zhang
Keyword(s):  
Surface Morphology ◽  
Cutting Force ◽  
Surface Quality ◽  
Single Point ◽  
Ferrous Metal ◽  
Minimum Quantity Lubrication ◽  
Diamond Turning ◽  
Machined Surface ◽  
Hard Particles ◽  
Machined Surface Quality

In the field of single-point diamond turning (SPDT), machining ferrous metal is an important research topic with promising application. For SPDT of ferrous metal, the influence of lubricant on the workpiece surface morphology remains to be studied. In this study, three lubricant machining environments were selected to carry out specific control experiments. The machined surface morphology and cutting force in different lubricant machining environments were analyzed. The experiment results showed that the lubricant environment will have significant impacts on the quality of the machined surface morphology of ferrous metal. In the environment of minimum quantity lubrication machining (MQLM-oil), better machined surface quality can be obtained than that in ordinary dry machining (ODM) and high-pressure gas machining (HGM). Furthermore, the cutting force captured in the ODM and HGM environment increased with the increase of the cutting depth, while the cutting force in the MQLM-oil environment remained almost unchanged. That indicates MQLM-oil can suppress the formation of hard particles to improve the machining quality.

scholarly journals Investigation on an Innovative Method for High-Speed Low-Damage Micro-Cutting of CFRP Composites with Diamond Dicing Blades

Materials ◽  
2018 ◽  
Vol 11 (10) ◽  
pp. 1974 ◽  
Author(s):  
Zewei Yuan ◽  
Jintao Hu ◽  
Quan Wen ◽  
Kai Cheng ◽  
Peng Zheng
Keyword(s):  
Surface Roughness ◽  
Rotational Speed ◽  
Fiber Orientation ◽  
High Speed ◽  
Machined Surface ◽  
Micro Cutting ◽  
Pull Out ◽  
Innovative Method ◽  
Cfrp Composites ◽  
Spindle Vibration

This paper presents an innovative method for high-speed micro-cutting of carbon fiber reinforced plastics (CFRP). It employs a diamond dicing blade for micromachining applications, with a thickness of about 200 μm and rotational speeds up to 30,000 rpm so as to meet the low-damage surface integrity requirements. The process parameters, cutting damage, surface roughness, and the spindle vibration were thoroughly investigated to evaluate and validate the method. The results indicate that a high cutting speed up to 76 m/s not only remarkably increases the rigidity of an ultra-thin dicing blade, but also decreases the cutting depth per diamond grit to below 10 nm, both of which are very conducive to obtaining a very fine machined surface of about Ra 0.025 μm, with no obvious damage, such as delamination, burrs, and fiber pull out. The serious spindle vibration limits the rotational speed to increase further, and the rotational speed of 25,000 rpm achieves the best fine machined surface. Furthermore, unlike most research results of the drilling and milling method, the proposed micro-cutting method obtains the maximum cutting current and surface roughness when cutting at 0° fiber orientation, while obtaining a minimum cutting current and surface roughness when cutting at 90° fiber orientation. The metal-bonded dicing blade achieves smaller surface roughness than the resin-bonded dicing blade. This paper also discusses the cutting mechanism by investigating the morphology of the machined surface and concludes that the micro breakage and plastic-flow in local regions of fibers and resin are the main material removal mechanisms for dicing CFRP composites with a diamond abrasive blade.

Study on Surface Roughness in High-Speed Milling for ALMn1Cu

2012 ◽  
Vol 157-158 ◽  
pp. 636-640 ◽  
Author(s):  
Zhen Hua Wang ◽  
Jun Tang Yuan ◽  
Jun Huang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
High Speed ◽  
Cutting Parameters ◽  
Factorial Experiments ◽  
Machined Surface ◽  
High Speed Milling ◽  
Machined Surface Quality ◽  
Cutting Experiments

Anti-rust aluminum is widely used in aviation, aerospace, communications, as well as weapons with non-corrosion, light, and other fine characteristic. In this study, in order to improve the machined surface quality and reduce the surface roughness and find the influence of the cutting parameters on the surface roughness, a series of cutting experiments for AlMn1Cu are conducted to obtain surface roughness values in high-speed milling. According to the analysis of variance (ANOVA) of factorial experiments, the cutting parameters significantly influencing on the surface roughness were presented.

scholarly journals Damage behavior in quasi-isotropic CFRP laminates with small fiber orientation angle mismatch

2016 ◽  
Vol 3 (1) ◽  
pp. 14-00422-14-00422
Author(s):  
Nurul Nabihah A. HAMID ◽  
Hayato NAKATANI ◽  
Shinji OGIHARA
Keyword(s):  
Fiber Orientation ◽  
Orientation Angle ◽  
Damage Behavior ◽  
Cfrp Laminates ◽  
Small Fiber ◽  
Fiber Orientation Angle

scholarly journals Molecular Dynamics Investigation of Residual Stress and Surface Roughness of Cerium under Diamond Cutting

Micromachines ◽  
2018 ◽  
Vol 9 (8) ◽  
pp. 386 ◽  
Author(s):  
Yao Li ◽  
Maobing Shuai ◽  
Junjie Zhang ◽  
Haibing Zheng ◽  
Tao Sun ◽  
...  
Keyword(s):  
Molecular Dynamics ◽  
Residual Stress ◽  
Surface Roughness ◽  
Surface Quality ◽  
Depth Of Cut ◽  
Formation Mechanisms ◽  
Machining Parameters ◽  
Diamond Cutting ◽  
Machined Surface ◽  
Machined Surface Quality

Machined surface quality in terms of residual stress and surface roughness has an important influence on the performance of devices and components. In the present work, we elucidate the formation mechanisms of residual stress and surface roughness of single crystalline cerium under ultraprecision diamond cutting by means of molecular dynamics simulations. Influences of machining parameters, such as the rake angle of a cutting tool, depth of cut, and crystal orientation of the workpiece on the machined surface quality were also investigated. Simulation results revealed that dislocation activity and lattice distortion are the two parallel factors that govern the formation of both residual stress and surface roughness. It was found that both distributions of residual stress and surface roughness of machined surface are significantly affected by machining parameters. The optimum machining parameters for achieving high machined surface quality of cerium by diamond cutting are revealed.

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