Analysis of Burr and Tear in Milling of Carbon Fiber Reinforced Plastic (CFRP) Using Finite Element Method

Wang, Fuji; Gu, Tianyu; Wang, Xiaonan; Jin, Xinghai; Zhang, Boyu

doi:10.1007/s10443-021-09896-w

Cited by 19 publications

(5 citation statements)

References 34 publications

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“…Currently, the CFRP finite element model are mainly divided into micro-scale model [27][28][29] and macro-scale model [30][31][32]. Macro-scale model is mostly used to investigate the cutting force, macroscopic machining morphology and interface damage of CFRP stacks.…”

Section: Finite Element Modeling Of Cfrp Helical Millingmentioning

confidence: 99%

Multi-objective grey correlation analysis based on CFRP helical milling simulation model

Zhou,

Wang,

et al. 2024

Preprint

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Helical milling is widely used in aerospace as a key processing technology for Carbon fiber reinforced polymer (CFRP). However, the eccentric machining characteristics lead to an unusually complex pattern of cutting force and residual stress distribution on the work-piece during helical milling processing. Based on the Hashin failure criterion, a 3D FEM model of CFRP helical milling was built for analyzing the changing law of cutting force, then the three factors and three levels orthogonal tests were used to investigate the influence of machining parameters on axial force, radial force and minimum principal residual stress, finally the multi-objective optimization based on grey correlation analysis was realized. Results showed that the errors of axial force and radial force obtained by simulation and experiment were 10.68% and 12.26%, respectively. The axial force and radial force were negatively correlated to the spindle speed, positively correlated to the axial cutting depth, and uncorrelated to the feed per tooth. The minimum principal residual stress was negatively correlated to the spindle speed, positively correlated to the feed per tooth, and uncorrelated to the axial cutting depth. The degree of influence on optimization of machining parameters was: spindle speed>axial cutting depth>feed per tooth. The corresponding average grey correlation degree differences were 0.280981, 0.216859 and 0.013422, respectively. The maximum value of grey correlation degree in the orthogonal test was 0.874372, and the corresponding optimal parameters combination was the spindle speed 8000 r/min, feed per tooth 0.03 mm/z and axial cutting depth 0.2 mm/r.

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Section: Finite Element Modeling Of Cfrp Helical Millingmentioning

confidence: 99%

Multi-objective grey correlation analysis based on CFRP helical milling simulation model

Zhou,

Wang,

et al. 2024

Preprint

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“…Protruding fiber bundles lead to much deeper top layer delamination than protrusions of separate fibers. In addition to the anisotropy and non-uniformity of fiber composites, Azmi et al [56] studied the tool wear mechanism and wear form in GFRP end milling and considered that the sharpness of the tool can affect the generation of delamination defects significantly. Hintze et al [54] obtained a similar conclusion on the slot milling of CFRP.…”

Section: Delaminationmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

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Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

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“…They concluded that the different thermal conductivity of CFRP with different fibre orientations is a key factor influencing the milling temperature and machining quality. Moreover, Wang et al [8] conducted finite element analysis (FEA) and experimental analysis of CFRP milling processes. They found that burr defects are more likely to form within the fibre cutting angle range of 0°< θ < 90°when a larger cutting edge radius is used.…”

Section: Introductionmentioning

confidence: 99%

Investigating the material removal mechanism and cutting performance in ultrasonic vibration-assisted milling of carbon fibre reinforced thermoplastic

Liu,

Sun,

et al. 2023

Mater. Res. Express

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Carbon fibre reinforced thermoplastic (CFRTP) has emerged as a sustainable alternative to carbon fibre reinforced plastic (CFRP) due to its improved reparability and recyclability. CFRTP, particularly carbon fibre reinforced polyetheretherketone (CF/PEEK), is a high-performance material known for its excellent mechanical, thermal, and corrosion resistance properties, making it well-suited for extreme environments in civil aviation equipment. However, machining processes such as milling often result in defects due to the material's high toughness and anisotropic nature. This study aims to investigate the material removal mechanism in ultrasonic-assisted milling (UAM) of CF/PEEK and compare the effects of fibre cutting angle (θ) and milling processes on milling performance. To simulate the fibre fracture mechanisms under different θ, finite element analysis (FEA) is employed. The results reveal different fracture modes, including bending, bending-shear, compression, and compression-shear, at various θ. Additionally, UAM demonstrates lower cutting forces and temperatures compared to conventional milling (CM). Notably, UAM greatly improves surface quality by reducing burr height and facilitating chip evacuation, while also enhancing surface integrity by minimizing cavity defects and fibre pull-out phenomena. These findings contribute to the development of low-damage machining methods that aim to achieve higher accuracy in CFRTP.

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Analysis of Burr and Tear in Milling of Carbon Fiber Reinforced Plastic (CFRP) Using Finite Element Method

Cited by 19 publications

References 34 publications

Multi-objective grey correlation analysis based on CFRP helical milling simulation model

Multi-objective grey correlation analysis based on CFRP helical milling simulation model

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Investigating the material removal mechanism and cutting performance in ultrasonic vibration-assisted milling of carbon fibre reinforced thermoplastic

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