Cutting Characteristics of CFRP Boards Using Electroplated Diamond Wire Tools

Abstract

CFRP (carbon fiber reinforced plastic), which is composed of carbon fibers in a resin matrix, is an extremely strong and light composite material that has found use in the aerospace and automotive industries. CFRP boards are very difficult to machine using common machining processes. Various machining artifacts, such as burrs and delamination, occur frequently when machining CFRP. Adequate techniques for machining CFRP have not yet been established. Recently, electroplated diamond wire machining technology has found use in cutting hard, brittle materials such as silicon and sapphire. In this study, we used an electroplated diamond wire saw to cut a CFRP workpiece. We quantified the cutting forces imposed on the workpiece and observed the surface state of the workpiece after cutting. We demonstrated that an electroplated diamond wire tool is suitable for the high-quality machining of CFRP boards.

Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

“…In comparison with the results published by Zhang and Tani [33], this study confirms an increase of process forces with increasing feed speed and decreasing cutting speed. As these processing parameters determine the depth of cut per cutting edge and forces increase with increasing depth of cut [17,29,30], these results were to be expected.…”

“…As these processing parameters determine the depth of cut per cutting edge and forces increase with increasing depth of cut [17,29,30], these results were to be expected. The study further confirms increasing roughness with increasing feed speed [3,33] and decreasing cutting speed [3]. The lower significance of grain density on process forces has been observed by Pala et al [17] for cutting silicon.…”

“…In order to show the economic potential of the wire cutting, the feed speed as well as the cutting speed are varied in the scope of this work. Lower range cutting and feed speeds have been analysed by Zhang and Tani [33]. However, the higher speed range increases productivity by exploiting the capability of the test rig and allows for the analysis of potential drawbacks such as excessive heat generation.…”

“…While the most popular trimming methods represented by machining with geometrically defined cutting edge and AWJM are extensively investigated by the research community, only little research work exists for wire sawing of CFRP. In this context, the most comprehensive experimental study was performed by Zhang and Tani [33] in 2017. The authors cut unidirectional (UD) CRFP plates with a fibre content of 67 vol.…”

Investigation on an Innovative Method for High-Speed Low-Damage Micro-Cutting of CFRP Composites with Diamond Dicing Blades

“…The surface roughness of the drilling or milling walls can be reduced to within the dimension of several micrometers. Even so, the machining quality cannot meet the requirements of CFRP composites in many new applications such as automobiles, laptop computers, space shuttles, and satellites [ 21 ]. These applications usually pursue submicrometer, or even better, cutting damage for CFRP composites.…”