An analytical method for predicting cutting forces in orthogonal machining of unidirectional composites

Jahromi, Ashkan S.; Bahr, Behnam

doi:10.1016/j.compscitech.2010.09.005

Cited by 98 publications

(7 citation statements)

References 13 publications

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“…Most studies devoted to cutting force prediction give similar results and conclusions. It has been found that this force primarily depends on the rake angle, fiber orientation and fracture toughness, as well as milling parameters [ 48 , 49 , 50 , 51 ].…”

Section: Introductionmentioning

confidence: 99%

Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Ciecieląg

Zaleski

2022

Materials

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The machining of thin-walled elements used in the aviation industry causes may problems, which create a need for studying ways in which undesirable phenomena can be prevented. This paper presents the results of a study investigating face milling thin-walled elements made of titanium alloy, aluminum alloy and polymer composite. These materials were milled with folding double-edge cutters with diamond inserts. The results of maximum vertical forces and surface roughness obtained after machining elements of different thicknesses and unsupported element lengths are presented. The results of deformation of milled elements are also presented. The results are then analyzed by ANOVA. It is shown that the maximum vertical forces decrease (in range 42–60%) while the ratio of vertical force amplitude to its average value increases (in range 55–65%) with decreasing element thickness and increasing unsupported element length. It is also demonstrated that surface roughness deteriorates (in range 100% for aluminum, 30% titanium alloy, 15% for CFRP) with small element thicknesses and long unsupported element lengths. Long unsupported element lengths also negatively (increasing deformation several times) affect the accuracy of machined elements.

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Section: Introductionmentioning

confidence: 99%

Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Ciecieląg

Zaleski

2022

Materials

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“…Pwu and Hocheng 10 proposed the analytical model of cutting forces based on the beam theory for 90° ﬁber orientation. Jahromi and Bahr 11 also derived the force expressions by modeling the fiber as a cantilever beam. The effects of buckling force and bending force on the total cutting forces were studied for the fiber orientations exceed 90°.…”

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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“…In addition to the numerical model, the results obtained through orthogonal tests can be very useful for producing a better formulation of an analytical model, such as that of Sahraie Jahromi et al [25], who developed an analytical model to predict the machining forces for the orthogonal machining of unidirectional polymer-matrix composites.…”

Section: Introductionmentioning

confidence: 99%

“…There is a lack of information on orthogonal cutting at a high cutting speed with linear displacement, because researchers mostly use modified milling machines, in which the cutter is fixed in the spindle of the milling machine, and the cutting speed is provided to the table [25,29]. Studies can also be found, in which a modified grinding machine is used to perform orthogonal cutting or turning machines to reach a higher cutting speed [17,18,24,30].…”

Section: Introductionmentioning

confidence: 99%

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

et al. 2019

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Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

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An analytical method for predicting cutting forces in orthogonal machining of unidirectional composites

Cited by 98 publications

References 13 publications

Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

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

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

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