A cutting force predicting model in orthogonal machining of unidirectional CFRP for entire range of fiber orientation

Reliable machining of carbon fiber-reinforced plastics (CFRP) is the key for application of these lightweight materials. Due to its anisotropy, CFRP is a very difficult material to machine because of occurring delamination and fiber-pullouts. The tool design is especially crucial to minimize and to avoid these processing errors. In this paper a process analysis for drilling is shown for better understanding of the chip formation. Drilling of unidirectional CFRP enables the investigation of the effect of fiber orientation on the chip formation process. In theory, the amount of cut fibers and the cutting angle to the main cutting edge determine the cutting force. Experimental tests with varied macroscopic drill geometries verify this theory. Based on these detected relationships, the tool loads can be calculated for a successful tool design.

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“…Chen et al set up a model for predicting the cutting forces, dividing the process into the areas: 0° < θ < 90°, 90° ≤ θ < 180°, and θ = 0° [31].…”

Section: Methodsmentioning

confidence: 99%

“…The applicability of cutting force modelling on the described strategy has to be investigated separately (cf. References [31][32][33]). …”

mentioning

confidence: 99%

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Sauer

Dix

Pütz

2018

JMMP

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“…For the cutting force prediction model in the CFRP orthogonal cutting, the most published literatures were focused on the equilibrium of cutting force, and three characteristic regions, i.e., chipping region, pressing region, and bouncing region, were analyzed respectively. The cutting force was obtained by resultant force of these three regions [19,20,33]. The energy model presented in this paper is based on the fracture toughness and chip thickness, the precision of the model is similar comparing with the force equilibrium method.…”

Section: Deformation and Debonding Depth Of Fibermentioning

confidence: 99%

An energy based force prediction method for UD-CFRP orthogonal machining

Qin

et al. 2017

Composite Structures

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Abstract:The machining of carbon fiber reinforced polymer (CFRP) composite presents a significant challenge to the industry, and a better understanding of machining mechanism is the essential fundament to enhance the machining quality. In this study, a new energy based analytical method was developed to predict the cutting forces in orthogonal machining of unidirectional CFRP with fiber orientations ranging from 0° to 75°. The subsurface damage in cutting was also considered. Thus, the total specific energy for cutting has been estimated along with the energy consumed for forming new surfaces, friction, fracture in chip formation and subsurface debonding. Experiments were conducted to verify the validity of the proposed model.

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“…1. The influence of fiber cutting angle has been widely investigated by many researchers [6,[10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26] in order to describe chip removal mechanisms in unidirectional CFRP.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

Geier

Pereszlai

2019

Period. Polytech. Mech. Eng.

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Measuring and characterizing of surface roughness of machined surfaces of carbon fiber reinforced polymer (CFRP) composites are difficult due to the occurrence of special surface damages (delamination, uncut fibers, fiber pull-outs or micro-cracks, etc.). The main objective of the present study is to analyze the characteristics of surface roughness of machined unidirectional CFRP in detail. Numerous conventional drilling, helical milling, and edge trimming experiments were carried out with different cutting tools in order to analyze the influence of them on the average surface roughness (Ra), on the roughness depth (Rz) and on the Rz /Ra parameter. The surface roughness was measured by a Mitutoyo SJ-400 contact profilometer and an Alicona Infinite Focus confocal microscope. The usability of the contact profilometer was experimentally tested and compared its results with the results of the confocal microscope. Experimental results show that the contact profilometer is suitable for measuring surface roughness of CFRP, furthermore, values of Rz /Ra of drilled and edge trimmed surfaces of unidirectional CFRP are changing in a wide interval: from 5 to 14 μm/μm due to the special surface damages. Based on this research, the machinability analysis of CFRP is suggested to be extended to the analysis of the Rz /Ra parameter.

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A cutting force predicting model in orthogonal machining of unidirectional CFRP for entire range of fiber orientation

Cited by 59 publications

References 28 publications

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

An energy based force prediction method for UD-CFRP orthogonal machining

Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

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