An analytical approach to cutting force prediction in milling of carbon fiber reinforced polymer laminates

Xiao, Jianzhang; Gao, Chongyang; Ke, Yinglin

doi:10.1080/10910344.2018.1449214

Cited by 22 publications

(20 citation statements)

References 28 publications

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“…This can be explained by the fact that, for high fiber angles (more than 45 • ), the double fiber removal actions of pulling and shearing lead to reduction in chip-tool contact length and thus reduce the friction. The rupture of fibers strongly depends also on the TFOA as well as the effective rake angle α, Equation (5) [60]. Figure 8 also shows that β decreases proportionally with an increase in the feed rate (i.e., chip thickness) for each unidirectional CFRP laminate when the cutting conditions are the same.…”

Section: Friction Anglementioning

confidence: 90%

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

et al. 2021

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Carbon fiber reinforced polymers (CFRPs) have found diverse applications in the automotive, space engineering, sporting goods, medical and military sectors. CFRP parts require limited machining such as detouring, milling and drilling to produce the shapes used, or for assembly purposes. Problems encountered while machining CFRP include poor tool performance, dust emission, poor part edge quality and delamination. The use of oil-based metalworking fluid could help improve the machining performance for this composite, but the resulting humidity would deteriorate the structural integrity of the parts. In this work the performance of an oil-in-water emulsion, obtained using ultrasonic atomization but no surfactant, is examined during the milling of CFRP in terms of fiber orientation and milling feed rate. The performance of wet milling is compared with that of a dry milling process. The tool displacement-fiber orientation angles (TFOA) tested are 0°, 30°, 45°, 60°, and 90°. The output responses analyzed were cutting force, delamination, and tool wear. Using atomized vegetable oil helps in significantly reducing the cutting force, tool wear, and fiber delamination as compared to the dry milling condition. The machining performance was also strongly influenced by fiber orientation. The interactions between the fiber orientation, the machining parameters and the tested vegetable oil-based fluid could help in selecting appropriate cutting parameters and thus improve the machined part quality and productivity.

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Section: Friction Anglementioning

confidence: 90%

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

et al. 2021

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“…1.41 cutting action of milling edge can be treated as an orthogonal cutting by using the equivalent method. 2 Heat transfer and heated layer at the machined surface…”

Section: Experiments Conditionmentioning

confidence: 99%

“…Carbon fiber reinforced polymer (CFRP) has been widely used in aviation industry benefiting from superior mechanical and physical properties, such as high strength and stiffness, low density, and corrosion resistance. 1,2 Although CFRP components are often manufactured in the near-net-shape, post machining operations are still required to satisfy the final assembly requirement and achieve the dimensional tolerance of the CFRP components. 3,4 However, it is still a challenge to machine CFRP with high quality owing to its strong anisotropy, nonhomogeneity, low thermal conductivity nature, which resulted in various machining defects including delamination, burrs, and subsurface damages.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of heat generation using a microscopic cutting model with thermo-mechanical coupling for carbon fiber reinforced polymer composites

Qian

Xiao

Wang

et al. 2020

Journal of Reinforced Plastics and Composites

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A three-dimensional micromechanical finite element cutting model with the thermo-mechanical coupling was developed for carbon fiber reinforced polymer composites in the paper. The finite element modeling considers the three phases of a composite, in which the interphase between the fiber and matrix can realize heat transfer and allow debonding to represent the failure of composites. The model predictions of the machining responses, such as cutting temperature and subsurface damage, at different fiber orientations were compared with various experimental data for model validation. It is indicated that the three phase micromechanical model is capable of precisely predicting cutting temperature and the damage induced by the cutting tool. It was found that cutting temperature and subsurface damage strongly depend on the fiber orientation. Subsurface damage is easily occurs in a fiber orientation range of 90°–135°, while the largest depth of the thermal damage occurs at 90°. In addition, the effect of machining parameters on the cutting temperature was investigated based on the cutting model. It was showed that the cutting speed should be reasonably selected to control the cutting temperature. The temperature decrease with increase the rake angle, while increase with increase depth of cut and radius of cutting edge.

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“…The composite coupons used in the experiment were the same as that in the previous work. 3,5 The mechanical properties of the UD-CFRP composites as well as its constituents are given in Tables 2 and 3, in which properties of composites, fiber, and matrix were obtained from the supplier’s specifications sheet, and the interfacial properties was calculated from the model developed in the previous work. 25 The cutting process was performed by using a diamond-coated and cemented carbide multi-edge cutter with a 10 mm diameter, 36 mm cutting length, 12 teeth, and a 15° helix angle, as shown in Figure 8(b).…”

Section: Experiments and Prediction Conditionmentioning

confidence: 99%

“…1–3 Despite the fact that composite parts are fabricated near-net shape, post machining of CFRP structures is an necessary procedure that assures the manufactured components meet their dimensional tolerances, surface quality, and other functional requirements. 4,5 However, machining of CFRP composites is considerably more difficult than machining of conventional metals and their alloys due to the obviously different material properties, such as anisotropy and nonhomogeneity nature, which are determined by the fiber type, microstructure, and matrix. 6 And these material characteristics in turn affect the machining quality of CFRP composites, especially the variation of cutting force and damage in machined surface.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the effects of microstructure on machining unidirectional carbon fiber reinforced polymer composites with a modified force model

Xiao

Gao

Wang

et al. 2019

Journal of Reinforced Plastics and Composites

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The paper aims to investigate the correlation of microstructural characteristics and machinability of unidirectional carbon fiber reinforced polymer composites by a modified analytical model. A representative volume element was selected to present the microstructure and analyze the force distribution, in which the interphase between the fiber and the matrix was considered significantly. And the microstructure can be obviously measured by using microscopic observation, especially the interphase was found to be around 0.3 μm in the used carbon fiber reinforced polymer composites. To study the representative volume element effect on the cutting behavior of unidirectional carbon fiber reinforced polymer composites, the prediction of cutting force was done by using a modified force model. Compared with the experiments, the developed model can well predict the cutting forces and subsurface damage in the carbon fiber reinforced polymer composites cutting. It was found that surface integrity as well as subsurface damage has a coincident varying trend with the fiber orientations, as confirmed by the observations of the machined surface at different fiber orientations. The good surface integrity can be obtained at the low fiber orientation of 0° and the poor surface occurs at the large fiber orientation of 135°. Moreover, the effect of interphase and the fiber volume fraction in representative volume element were further investigated. The results show that the cutting forces increase with increasing the fiber volume fraction as well as the interphase volume fraction, and the interphase affects the cutting force in the transverse direction is significantly higher than that in longitudinal direction.

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An analytical approach to cutting force prediction in milling of carbon fiber reinforced polymer laminates

Cited by 22 publications

References 28 publications

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

Evaluation of heat generation using a microscopic cutting model with thermo-mechanical coupling for carbon fiber reinforced polymer composites

Investigation on the effects of microstructure on machining unidirectional carbon fiber reinforced polymer composites with a modified force model

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