Surface Roughness Study of Milled Carbon Fiber Reinforced Polymer (CFRP) Composite Using 4 mm 2-Flute Titanium Aluminum Nitride (TiAlN) Coated Carbide End Mills

2014 ◽  
Vol 887-888 ◽  
pp. 1101-1106 ◽  
Author(s):  
Mohamed Konneh ◽  
Sudin Izman ◽  
Mirza Emmil Dzahi Padil ◽  
Rosniza Roszat
Keyword(s):  
Surface Roughness ◽  
Weight Ratio ◽  
High Strength ◽  
Milling Process ◽  
Machining Parameters ◽  
Inherent Anisotropy ◽  
Pull Out ◽  
Cfrp Composite ◽  
End Mills ◽  
Coated Carbide

As the goal for aircraft weight reduction and low fuel consumption becomes a dire concern in aerospace industries, there is driving desire for the increasing use of advanced exotic materials such as composites, titanium and Inconels in the aerospace industry because of their high strength to weight ratio. Nevertheless the inherent anisotropy, inhomogeneous properties of CFRP and low bonding strength within the laminates make machining of these composite materials results in several undesirable effects such as delamination, micro-cracking, burr, fiber pull out and breakage. This paper discusses an experimental investigation into the influence of machining parameters on surface roughness when milling CFRP using 4 mm-diameter 2-fluted carbide end-mill coated with Titanium Aluminium Nitride (TiAlN). Relationship between the machining variables and the output variables is established and a mathematical model is predicted for the surface roughness produced during the milling process for the machining conditions investigated.

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.

Experimental Study on Milling Hardened SKD Steel Using Micro CBN Ball-End Mills

2010 ◽  
Vol 126-128 ◽  
pp. 773-778
Author(s):  
Yung Tien Liu ◽  
Neng Hsin Chiu ◽  
Yen Chun Lin ◽  
Chih Liang Lai ◽  
Yu Fu Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Machined Surface ◽  
Performance Function ◽  
End Mills

Micro ball-end milling process features the ability of machining complex surfaces, precision machining accuracy, and excellent machined surface roughness. However, because the diameter of a micro milling tool is very small, a rapid progress of tool wear or even tool breakage usually happens when machining a high-strength hardened mold steel using improper machining parameters. As a result, the machining cost would rise due to the quality defect in machined workpiece. In this study, to investigate how the machining parameters affect the cutting behaviors, a series of experiments using micro CBN ball-end mills with a diameter of 0.5 mm were performed to cut the SKD11 mold steel with hardness of HRC 61. The machining parameters are selected as the feeding speed (f) being 840, 960 and 1,080 mm/min, depth of cut (ap) being 30, 45, 60 μm, and spindle speed (vs) being fixed as 30,000 rpm. According to the experimental results, the measured three-axis cutting forces, flank wears, and surface roughness of machined workpiece are highly related to the cutting length. It is expected that the measured results can be used to construct a performance function of a micro ball-end tool. With referring to the performance function, the tool life can be well expected, and thus a progress in machining efficiency without tool failure can be achieved.

scholarly journals Effect of Machining Parameters on Surface Roughness During Milling Operation

2021 ◽  
Author(s):  
Sajid Raza Zaidi ◽  
Mushtaq Khan ◽  
Syed Husain Imran Jaffery ◽  
Salman Sagheer Warsi
Keyword(s):  
Energy Consumption ◽  
Surface Finish ◽  
Cutting Speed ◽  
Weight Ratio ◽  
High Strength ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Sustainable Machining ◽  
Considerable Impact

Aluminum is one of the most extensively used metal in aerospace industry and other applications due to its corrosion resistance, good machineability excellent mechanical properties and high strength to weight ratio. Machining parameters like number of inserts, depth of cut, cutting speed, feed rate, and cutting tool diameter have considerable impact on production rate, surface finish, energy consumption and sustainable machining. Suitable process parameters during machining and specifically milling process not only leads towards better surface finish but also towards sustainable machining. Aim of machining has always been to produce parts with better surface quality and lower energy consumption. To study the effect of milling parameters on the surface finish, Taguchi L9 array was employed for experimentation. The outcome of each parameter on surface finish has been examined using ANOVA and the most considerable parameters were identified. It has also been observed that the number of inserts significantly influence the surface finish.

Study on carbon epoxy composite surfaces machined by abrasive water jet machining

2018 ◽  
Vol 53 (20) ◽  
pp. 2909-2924 ◽  
Author(s):  
Ajit Dhanawade ◽  
Shailendra Kumar
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Process Parameters ◽  
Surface Finish ◽  
Epoxy Composite ◽  
Water Jet ◽  
Machining Parameters ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Pull Out

Traditional machining of carbon epoxy composite material is difficult due to excessive tool wear, excessive stresses and heat generation, delamination, high surface waviness, etc. In the present paper, research work involved in the experimental study of abrasive water jet machining of carbon epoxy composite material is described. The aim of present work is to improve surface finish and studying defects in machined samples. Taguchi's orthogonal array approach is used to design experiments. Process parameters namely hydraulic pressure, traverse rate, stand-off distance and abrasive mass flow rate are considered for this study. Analysis of machined surfaces and kerf quality is carried out using scanning electron microscope to evaluate microscopic features. Further, the effect of machining parameters on surface roughness is investigated using analysis of variance approach. It is found that traverse rate and pressure are most significant parameters to control surface roughness. Optimization of process parameters is performed using grey relational analysis. Thereafter, confirmation tests are carried out to verify the improvement in the surface quality with optimum set of process parameters. It is found that surface finish of machined samples is improved by 10.75% with optimum levels of process parameters. Defects like delamination, fiber pull-out and abrasive embedment are also studied using SEM. It is observed that delamination and fiber pull-out are prominent in samples machined at low pressure and high traverse rate.

ADDITIVE MANUFACTURING PARAMETERS OPTIMIZATION OF Ti6AL4V ELI FOR MEDICAL IMPLANTS

2022 ◽  
Author(s):  
VIJAY KUMAR MEENA ◽  
PARVEEN KALRA ◽  
RAVINDRA KUMAR SINHA
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Weight Ratio ◽  
High Strength ◽  
Surface Characteristics ◽  
Parameters Optimization ◽  
Medical Implants ◽  
Scan Speed ◽  
Grey Relational ◽  
Manufacturing Parameters

Additive manufacturing (AM) of titanium (Ti) alloys has always fascinated researchers owing to its high strength to weight ratio, biocompatibility, and anticorrosive properties, making Ti alloy an ideal candidate for medical applications. The aim of this paper is to optimize the AM parameters, such as Laser Power (LP), Laser Scan Speed (LSS), and Hatch Space (HS), using Analysis of Variance (ANOVA) and Grey Relational analysis (GRA) for mechanical and surface characteristics like hardness, surface roughness, and contact angle, of Ti6Al4V ELI considering medical implant applications. The input parameters are optimized to have optimum hardness, surface roughness and hydrophilicity required for medical implants.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

scholarly journals Experimental Investigation of Fatigue Debonding Growth in FRP–Concrete Interface

Materials ◽  
2020 ◽  
Vol 13 (6) ◽  
pp. 1459 ◽  
Author(s):  
Xinzhe Min ◽  
Jiwen Zhang ◽  
Chao Wang ◽  
Shoutan Song ◽  
Dong Yang
Keyword(s):  
Growth Rate ◽  
Weight Ratio ◽  
High Strength ◽  
Load Level ◽  
Experimental Results ◽  
Fatigue Load ◽  
Load Range ◽  
Pull Out ◽  
Reinforced Polymer ◽  
Externally Bonded

An externally bonded fiber reinforced polymer (FRP) plate (or sheet) is now widely used in strengthening bending members due to its outstanding properties, such as a high strength to weight ratio, easy operating, corrosion and fatigue resistance. However, the concrete member strengthened by this technology may have a problem with the adhesion between FRP and concrete. This kind of debonding failure can be broadly classified into two modes: (a) plate end debonding at or near the plate end, and (b) intermediate crack-induced debonding (intermediate crack-induced (IC) debonding) near the loading point. The IC debonding, unlike the plate end debonding, still needs a large amount of investigation work, especially for the interface under fatigue load. In this paper, ten single shear pull-out tests were carried out under a static or fatigue load. Different load ranges and load levels were considered, and the debonding growth process was carefully recorded. The experimental results indicate that the load range is one of the main parameters, which determines the debonding growth rate. Moreover, the load level can also play an important role when loaded with the same load range. Finally, a new prediction model of the fatigue debonding growth rate was proposed, and has an excellent agreement with the experimental results.

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