Design of Exotic Materials Machining System

2013 ◽  
Vol 633 ◽  
pp. 36-46 ◽  
Author(s):  
John Mo ◽  
Song Lin Ding ◽  
Andrew Mackie ◽  
Milan Brandt ◽  
Shou Jin Sun ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Cubic Boron Nitride ◽  
Polycrystalline Diamond ◽  
Gain Scheduling ◽  
Control System Design ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Machining System ◽  
Design Requirements ◽  
Fiber Reinforced Plastics

New exotic materials such as titanium alloys and carbon fiber reinforced plastics require strong hard cutters made of cubic boron nitride or polycrystalline diamond. However, the traditional mechanical diamond grinding process is slow and causes damage to the workpiece. This chapter examines the design requirements of an electrical discharge machining system that can be used to machine polycrystalline diamond tipped carbide drills. A preliminary theoretical model is described but the system complexity requires a gain scheduling approach to the control system design.

scholarly journals Effects of Nano Organoclay and Wax on the Machining Temperature and Mechanical Properties of Carbon Fiber Reinforced Plastics (CFRP)

2019 ◽  
Vol 3 (3) ◽  
pp. 85 ◽  
Author(s):  
El-Ghaoui ◽  
Chatelain ◽  
Ouellet-Plamondon ◽  
Mathieu
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
Polycrystalline Diamond ◽  
Fiber Reinforced ◽  
Cfrp Laminates ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced ◽  
Pcd Tools

Carbon fiber reinforced plastics (CFRP) are appreciated for their high mechanical properties and lightness. Due to their heterogeneous nature, CFRP machining remains delicate. Damages are caused on the material and early tool wear occurs. The present study aims to evaluate the effects of fillers on CFRP machinability and mechanical behavior. CFRP laminates were fabricated by the vacuum assisted resin transfer molding (VARTM) process, using a modified epoxy resin. Three fillers (organoclay, hydrocarbon wax, and wetting agent) were mixed with the resin prior to the laminate infusion. Milling tests were performed with polycrystalline diamond (PCD) tools, equipped with thermocouples on their teeth. Machinability was then studied through the cutting temperatures and forces. Tensile, flexural, and short-beam tests were carried out on all samples to investigate the effects of fillers on mechanical properties. Fillers, especially wax, allowed us to observe an improvement in machinability. The best improvement was observed with 1% wax and 2% organoclay, which allowed a significant decrease in the cutting forces and the temperatures, and no deteriorations were seen on mechanical properties. These results demonstrate that upgrades to CFRP machining through the addition of nanoclays and wax is a path to explore.

High Aspect Ratio Machining of Carbon Fiber Reinforced Plastics by Electrical Discharge Machining Process

2020 ◽  
Author(s):  
Cibi Makudapathy ◽  
Murali Sundaram
Keyword(s):  
Carbon Fiber ◽  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics

Abstract Micromachining of Carbon Fiber Reinforced Plastics (CFRPs) is essential for numerous applications in several industries such as aerospace, automotive, defense, shipping, sporting goods, and biomedical industries. The major challenge in machining CFRP by electrical discharge machining (EDM) is due to the non-conductivity of epoxy material which is used as a binder for manufacturing these CRFPs. This study attempts a novel, yet simple approach to ensure the conductivity of the work piece through the entire machining process. Experiments were carried out in this work to assess the feasibility of machining high aspect ratio micro-holes in CFRP by micro EDM. The effect of process parameters such as voltage and feed-rate on the hole quality was studied. Using optimal process conditions, micro hole of 2500 µm deep with an aspect ratio of over 11 was achieved.

Experimental Study on Micro Milling of Carbon Fiber Reinforced Plastics

2016 ◽  
Vol 836-837 ◽  
pp. 185-190 ◽  
Author(s):  
Xian Wu ◽  
Liang Li ◽  
Ning He ◽  
Xiu Qing Hao
Keyword(s):  
Experimental Study ◽  
Carbon Fiber ◽  
Diamond Tool ◽  
Polycrystalline Diamond ◽  
Micro Milling ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

Recently the demands for miniature component of varying materials have been rapidly increasing in aerospace industry. Carbon fiber reinforced plastics is widely used as functional or structural material due to its superior material properties. It also is one of the difficult to machine materials because of the poor machinability. This paper presents an experimental study on micro milling of carbon fiber reinforced plastics with self-developed polycrystalline diamond tool. Cutting force and specific cutting energy are analyzed. The minimum chip thickness and carbon fiber diameter are found to have great effect on the cutting force signature peak. Tool wear mechanism of polycrystalline diamond tool also is investigated.

Investigation of cBN Electroplated End-Mill Shape for CFRP Machining

2016 ◽  
Vol 874 ◽  
pp. 463-468
Author(s):  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa ◽  
Kiyofumi Inaba ◽  
...  
Keyword(s):  
High Efficiency ◽  
Cubic Boron Nitride ◽  
Rake Angle ◽  
Machining Process ◽  
End Mill ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
End Mills ◽  
High Thermal Resistance ◽  
Fiber Reinforced Plastics

Currently, carbon fiber reinforced plastics (CFRP) are being increasingly adopted in various fields. Thus, machining CFRP with high accuracy and high efficiency is required. In addition, machining stack materials composed of CFRP and titanium alloys is required. Therefore, in this study, a novel end-mill electroplated with a cubic boron nitride (cBN) abrasive, which has high thermal resistance, is proposed. In order to evaluate the influence of the base metal shape of the proposed end-mill on the machining process, several cBN-electroplated end-mills with different rake angles or chamfers were fabricated and used to cut CFRP. In addition, in order to evaluate the abrasive shape, a blocky abrasive was also electroplated on the end-mill. The results indicate that the negative rake angle is useful to restrain the progression of tool wear. However, in order to obtain the element of cutting and grinding, it is required that the rake angle should be positive. Moreover, the reasonable width of chamfer is effective for restraining the increase in CFRP temperature. Further, a sharp shaped abrasive can more effectively generate a CFRP with a sharp edge compared with a blocky shape abrasive.

Sign in / Sign up

Export Citation Format

Share Document