The Machinability of CFRP with Cutting Movement of End-Milling

2015 ◽  
Vol 656-657 ◽  
pp. 391-397 ◽  
Author(s):  
Takashi Inoue ◽  
Masahiro Hagino ◽  
Kazushige Tokuno ◽  
Hiroshi Usuki ◽  
Junji Miyamoto
Keyword(s):  
Carbon Fiber ◽  
Surface Finish ◽  
Fiber Orientation ◽  
End Milling ◽  
Cutting Temperature ◽  
Helix Angle ◽  
Finish Cutting ◽  
Cfrp Composite ◽  
End Mills ◽  
Machining Operations

Recently, carbon fiber reinforced plastics (CFRP) are expected to be used more in the aerospace and automotive industries, because of their outstanding lightweight material characteristics and tensile strength [1][2]. Underlying this are problems closely related to improvement of the earth’s environment. However, a mechanical property is influenced by the difference in the distribution state of the carbon fiber, and the adhesion intensity of the binding material. Moreover, they have the characteristic of intense anisotropy, strength wise depending on the orientation of the carbon fibers [3][4]. Therefore, CFRPs are considered difficult-to-machine materials [5], because the surface finish deteriorates according to the carbon fiber orientation. Establishing the optimal cutting conditions to solve such problems also from an economical viewpoint is essential. In our study, end milling operations of different carbon fiber orientation CFRP composite material were investigated with three kinds of different helix angle end mills. Evaluations were based on the surface finish, cutting force and cutting temperature. Moreover, the relationships between the carbon fiber orientation and the machining operations were determined. We earlier evaluated the machinability from the relationship between carbon fiber orientation and tool helix angle by down-cut milling to solve these problems [6]. In this study, machining operations of different carbon fiber orientation CFRP composite material were investigated with three kinds of different helix angle end mills by up-cut milling. Evaluations were based on the surface finish, cutting force and cutting temperature. Moreover, the results of this experiment were compared with the results of down-cut milling.

scholarly journals Effect of Carbon Fiber Orientation and Helix Angle on CFRP Cutting Characteristics by End-Milling

2013 ◽  
Vol 7 (3) ◽  
pp. 292-299 ◽  
Author(s):  
Masahiro Hagino ◽  
◽  
Takashi Inoue ◽  
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
Surface Finish ◽  
Fiber Orientation ◽  
End Milling ◽  
Cutting Speed ◽  
Helix Angle ◽  
Depth Of Cut ◽  
Reinforced Plastics ◽  
End Mills

Carbon Fiber Reinforced Plastics (CFRP) have outstanding lightweight material characteristics and tensile strength. The use of CFRP in aerospace industry has been successfully implemented and is expected to grow in the future. However, the mechanical properties of CFRP are affected by differences in the distribution and orientation of the carbon fibers and their adhesion to the binding material. CFRP shows intense anisotropy in strength of carbon fiber depending on its mechanical properties and the state of the carbon fiber orientation. Therefore, the tool life shortest and the surface finish quality of the material becomes unstable and eventually difficult to cut. This paper presents the effect on carbon fiber orientation and helix angle with CFRP cutting characteristics by end milling. Here, three types of orientations weremachined by straight type end mills and constant cutting conditions with a cutting speed 70 m/min, a feed rate 0.056 mm/tooth and 3 mm depth of cut. Our results showed that the tool helix angle 0° gave a better surface finish than the other tools, irrespective of the fiber orientation. The helix angle is greatly affected by the exposure of the fibers from the surface. Axial force (Fz) is negligible quantity for helix angle 0°, and cutting force is low. The carbon fiber orientation of 45° and -45° has exfoliation-like dimples.

Experimental Investigation to Study Cutting Temperature During Milling of Unidirectional Carbon Fiber Reinforced Plastic

2014 ◽  
Author(s):  
Seyedbehzad Ghafarizadeh ◽  
Jean-François Chatelain ◽  
Gilbert Lebrun
Keyword(s):  
Carbon Fiber ◽  
Tool Wear ◽  
Fiber Orientation ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Mechanical And Thermal Properties ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced

The surface machining of Carbon Fiber Reinforced Plastics (CFRP) materials is a challenging process, given the heterogeneity and anisotropic nature of these composites, which, combined with the abrasiveness of the fibers involved, can produce some surface damage and extensive tool wear. The cutting temperature is one of the most important factors associated with the tool wear rate and machinability of these materials, which are also affected by the mechanical and thermal properties of the work material and the cutting conditions. In this work, the cutting temperature, forces and surface roughness were measured under different cutting conditions during the ball-end milling of unidirectional CFRP. Cutting speeds ranging from 200 to 350 m/min, a feed rate of 0.063 mm/rev, fiber orientation of (the angle between carbon fibers and feed direction) 0, 45, 90 and 135 degrees, and a 0.5 mm depth of cut were used. The results show that the cutting speed and fiber orientation have a significant influence on the cutting temperature and cutting force. The maximum and minimum cutting forces and temperature were achieved for fiber orientations of 90 and 0 degrees, respectively.

Finding Cutter Engagement for Ball End Milling of Tessellated Free-Form Surfaces

2005 ◽  
Author(s):  
Zhiyang Yao
Keyword(s):  
Surface Finish ◽  
Feed Rate ◽  
End Milling ◽  
Geometric Algorithms ◽  
Free Form ◽  
Ball End Milling ◽  
Final Surface ◽  
End Mills ◽  
Free Form Surfaces ◽  
Final Surface Finish

In fabricating free-form surfaces, ball end mills are mainly used to reach the final surface finish requirements. In the milling processes, cutter engagement value measures what portion of the cutter is involved in machining at a given instant of time. This paper presents geometric algorithms for estimating cutter engagement values for ball end milling processes of tessellated free-form surfaces. The cutter engagement value calculated here can be used later on in generating efficient cutter paths, as well as performing adaptive feed rate controls.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

Thermal characteristics of unidirectional carbon fiber reinforced polymer laminates during orthogonal cutting

2018 ◽  
Vol 37 (13) ◽  
pp. 905-916 ◽  
Author(s):  
Qinglong An ◽  
Jie Chen ◽  
Xiaojiang Cai ◽  
Tingting Peng ◽  
Ming Chen
Keyword(s):  
Carbon Fiber ◽  
Fiber Orientation ◽  
Cutting Temperature ◽  
Orientation Angle ◽  
Fiber Reinforced Polymer ◽  
Carbon Fiber Reinforced Polymer ◽  
Fiber Reinforced ◽  
Reinforced Polymer ◽  
Fiber Orientation Angle ◽  
Carbon Fiber Reinforced

Carbon fiber reinforced polymer has been used as a major material for primary load-bearing structural components in aviation industry. But its poor heat resistance is an important factor affecting the machining performance, because high cutting temperature above glass transition temperature of resin matrix (normally 300°C or below) may lead to the degradation of the resin matrix. In this study, orthogonal machining experiments were conducted to investigate the effects of cutting parameters, cutting tool geometric parameters, and material parameters on cutting temperature, and the prediction model of cutting temperature about fiber orientation angle ( θ) was built. Cutting temperature was measured by semiartificial thermocouple method. The experimental results revealed that the influence of cutting parameters on cutting temperature was not affected by fiber orientation angle of carbon fiber reinforced polymer. Cutting tool geometric parameters have little effect on cutting temperature. Unlike metal materials, cutting temperature was greatly influenced by θ. Cutting temperature for θ < 90° was significantly higher than that for θ > 90°. The maximum temperature occurred at θ = 90°. The influence of fiber orientation angle was shown in two aspects: changing the springback of unidirectional-carbon fiber reinforced polymer laminates in cutting process, changing material removal mechanism, which affected cutting temperature eventually.

Turning and Drilling Machinability of Recycled Aluminum Alloys

2016 ◽  
Vol 710 ◽  
pp. 77-82
Author(s):  
Jean Brice Mandatsy Moungomo ◽  
Donatien Nganga Kouya ◽  
Victor Songmene
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloys ◽  
Surface Finish ◽  
Cutting Forces ◽  
Quality Characteristics ◽  
Part Quality ◽  
Aluminum Chips ◽  
Finish Cutting ◽  
Dry And Wet Conditions ◽  
Machining Operations

A great deal of effort and research has been dedicated to recycled aluminum alloys, mainly to recycling processes and to the mechanical properties of recomposed parts; however, very limited work has been oriented towards the machinability of recycled aluminum materials. Recycled and recomposed aluminum parts sometimes need machining to obtain the final usable part shape and for assembly purposes. The acceptability of using recycled materials in design and engineering applications depends not only on their mechanical properties, but also on their machinability. This paper investigates the machinability of recycled aluminum alloys based on surface finish, cutting forces and chip formation. Two recycled foundry aluminum alloys were used: one from aluminum can covers and another from aluminum chips produced during machining. The machining operations investigated included turning and drilling under dry and wet conditions. The two tested recycled aluminum alloys showed different machinability behaviors and different part quality characteristics, suggesting that it would be desirable to consider separating aluminum wastes and chips considered for recycling by origin or type prior to melting and recasting.

Generating Spiral Paths for Sculptured Surfaces Machining

2006 ◽  
Author(s):  
Zhiyang Yao
Keyword(s):  
Surface Finish ◽  
End Milling ◽  
Sculptured Surfaces ◽  
Cutting Efficiency ◽  
Final Surface ◽  
Cutter Path ◽  
End Mills ◽  
Cusp Height ◽  
Major Factors ◽  
Final Surface Finish

To machine sculptured surfaces, ball end mills are mainly used to reach the final surface finish requirements. During machining, the cusp height is one of the major factors defining the final surface finish smoothness. A cutter path that maintains a high cutting efficiency as well as a constant cusp height is desired. Spiral curves, with the property of not requiring extra linkage segments between two adjacent arms can be used to generate a smooth cutter path. In this paper, a geometric algorithm for generating spiral cutter paths for ball end milling in machining sculptured surfaces is presented.

Experimental Study on Orthogonal Cutting of 0° T700/LT03A CFRP Uniform Laminates

2014 ◽  
Vol 800-801 ◽  
pp. 76-80 ◽  
Author(s):  
Sheng Qin ◽  
Zheng Wei Li ◽  
Hong Zhou Zhang ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Carbon Fiber ◽  
Fiber Orientation ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Fiber Reinforced Polymers ◽  
Carbon Fiber Reinforced Polymers ◽  
Machine Material ◽  
Reinforced Polymers ◽  
Specific Strength ◽  
Strength And Stiffness

Carbon fiber reinforced polymers (CFRP) are increasingly used in aerospace and other industries, due to its high specific strength and stiffness. Machining operations are involved between forming fabrication and assembling as a fining process, during which defects like delamination, burrs and splintering are the main cause of substandard products. This is because that CFRP is a typical difficult to machine material with distinct anisotropy and heterogeneity. Thus machinability of CFRP material under different fiber orientations is a main issue. This paper intensively investigated on cutting forces and temperatures when orthogonal cutting of 0° T700/LT03A CFRP uniform laminates, with fiber orientation from 0°to 180°. Material removal mechanisms and carbon fiber fraction modes under various fiber orientations were discussed. The results showed that fiber orientation of 90°is the worst scenario of cutting, under which condition the force and temperature of the highest level, while that of 150°indicates the other. The results of cutting temperature indicated that it is mainly from the friction heat in the zone III generated by the thrust force.

A finishing process via ultrasonic drilling for additively manufactured carbon fiber composites

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Pedram Parandoush ◽  
Palamandadige Fernando ◽  
Hao Zhang ◽  
Chang Ye ◽  
Junfeng Xiao ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Cutting Force ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Burr Formation ◽  
Carbon Fiber Composites ◽  
Ultrasonic Power ◽  
Content Type ◽  
Fused Deposition

Purpose Additively manufactured objects have layered structures, which means post processing is often required to achieve a desired surface finish. Furthermore, the additive nature of the process makes it less accurate than subtractive processes. Hence, additive manufacturing techniques could tremendously benefit from finishing processes to improve their geometric tolerance and surface finish. Design/methodology/approach Rotary ultrasonic machining (RUM) was chosen as a finishing operation for drilling additively manufactured carbon fiber reinforced polymer (CFRP) composites. Two distinct additive manufacturing methods of fused deposition modeling (FDM) and laser-assisted laminated object manufacturing (LA-LOM) were used to fabricate CFRP plates with continuous carbon fiber reinforcement. The influence of the feedrate, tool rotation speed and ultrasonic power of the RUM process parameters on the aforementioned quality characteristics revealed the feasibility of RUM process as a finishing operation for additive manufactured CFRP. Findings The quality of drilled holes in the CFRP plates fabricated via LA-LOM was supremely superior to the FDM counterparts with less pullout delamination, smoother surface and less burr formation. The strong interfacial bonding in LA-LOM proven to be superior to FDM was able to endure higher cutting force of the RUM process. The cutting force and cutting temperature overwhelmed the FDM parts and induced higher surface damage. Originality/value Overall, the present study demonstrates the feasibility of a hybrid additive and subtractive manufacturing method that could potentially reduce cost and waste of the CFRP production for industrial applications.

Ball End Milling of Glass with Inclined Cutter

2010 ◽  
Vol 33 ◽  
pp. 195-199 ◽  
Author(s):  
Yu Xia Qin ◽  
Ji Hong Jia ◽  
Zhi Wei ◽  
Mei Lin Gu ◽  
Tong Hui Li ◽  
...  
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
End Milling ◽  
Double Helix ◽  
Helix Angle ◽  
Milling Process ◽  
Rotational Axis ◽  
Machined Surface ◽  
Ball End Milling ◽  
Cutting Processes

This study deals with the effect of tool–surface inclination on cutting forces in ball end milling .Since glass undergoes almost no elastic deformation, the shape of the cutter in glass machining has a larger influence on surface finish than that of metal machining. Model of geometry and tilt tool milling process is established. A double helix micro-flute ball end mill made of cemented carbide is used in the groove milling tests with radius 0.5mm at a helix angle of 30°. The rotational axis of the tool is inclined to improve the surface finish. The cutting processes are modeled, and 3-direction cutting forces are measured via three groups of experiments to show the effect of the tool inclination on the machined surface. Several micro grooves, then, are machined with the crack-free surfaces to prove efficiency and surface quality in the milling process.

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