Effect of Cutting Fluid Delivery Method on Ultrasonic Assisted Edge Trimming of Multidirectional CFRP Composites at Different Machining Conditions

Helmy, Mohamed O.; El-Hofy, Mohamed; El-Hofy, Hassan

doi:10.1016/j.procir.2017.12.077

Cited by 29 publications

(10 citation statements)

References 21 publications

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“…Cutting force reduction due to lower chip load suppresses delamination in RUAT. These results are agreed with the findings by Helmy et al [21]. The effect of ultrasonic amplitude on delamination occurrence seems insignificant, as seen in Figure 8.…”

Section: Discussionsupporting

confidence: 93%

Analysis of Carbon Fiber-Reinforced Polymer Composites Delamination during Vibration Assisted Trimming using Historical Data Design

Kasim

Mohamad

Izamshah

et al. 2021

MJCSM

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Delamination is one of the main issues during the CFRP cutting process. This problem attracts researchers to investigate to meet the stringent quality need. This paper evaluates the influence of Rotary Ultrasonic Assisted Trimming (RUAT) when slotting carbon fiber reinforced plastic (CFRP). The study investigates rotation speed, vibration amplitude, and frequency particularly. The correlation effect of these parameters is to be evaluated by response surface methodology (RSM) to identify the minimum delamination. Seventeen trials were conducted with 38 plies of multi-directional CFRP panel. The trimming quality was determined by the minimum delamination damage of the slotting area analyzed by the ImageJ software. The best slotting quality can be achieved by applying spindle speed, amplitude, and frequency of 5305 rpm, 2.75 µm, and 26.79 kHz.

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Section: Discussionsupporting

confidence: 93%

Analysis of Carbon Fiber-Reinforced Polymer Composites Delamination during Vibration Assisted Trimming using Historical Data Design

Kasim

Mohamad

Izamshah

et al. 2021

MJCSM

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“…One possible reason is that part of the lubricant flows into the cavity during MQL-assisted CFRP machining, which leads to the formation of insufficient lubricating film. Through the CFRP milling experiment, Iskandar et al [190] found that the spray mode that combined high air flow and low oil flow promoted the breakup mechanism of droplets, and the best spray effect was obtained. It also produces a more coherent jet with less vortex formation and better penetration into the cutting area.…”

Section: Minimum Quantity Lubricationmentioning

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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“…AWJ has the limitations of high operation cost, abrasive slurry collection, and low material removal rate, despite producing holes with small thermal damage [ 16 , 17 ]. A low material removal rate and tool wear also limit the utilization of USM [ 18 ]. As a promising alternative method, laser processing has the characteristics of a small spot radius, high power density, and strong directivity [ 19 , 20 , 21 ].…”

Section: Introductionmentioning

confidence: 99%

Hole Morphology and Keyhole Evolution during Single Pulse Laser Drilling on Polyether-Ether-Ketone (PEEK)

Zhang

Tian

et al. 2022

Materials

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Polyether-ether-ketone (PEEK), with its superior mechanical, chemical, and thermal properties, as well as high biocompatibility, has been used in aerospace, electronics, and biomedical applications. In this paper, a large number of experiments of single-pulse laser drilling on PEEK were performed to analyze the hole morphology and keyhole evolution, which were characterized by an optical microscope, charge-coupled device (CCD), and high-speed camera. A novel method is proposed to observe and measure the dimension of the processed hole rapidly right after laser drilling for special polymer materials with wear-resistance and non-conductivity. Morphological characteristics of holes are presented to illustrate the effect of pulse width and peak power on hole depth, hole diameter, and aspect-ratio. The obtained maximum drilling depth was 7.06 mm, and the maximum aspect-ratio was 23. In situ observations of the dynamic process of laser drilling, including the keyhole evolution together with ejection and vaporization behavior, were also carried out. The keyhole evolution process can be divided into three stages: rapid increment stage (0–2 ms) at a rate of 2.1 m/s, slow increment stage (2–4 ms) at a rate of 0.3 m/s, and stable stage (>4 ms). Moreover, the variation of dimensionless laser power density with the increase in pulse width was calculated. The calculated maximum drilling depth based on energy balance was compared with the experimental depth. It is proven that the laser–PEEK interaction is mainly influenced by a photothermal effect. Ejection is the dominant material-removal mechanism and contributes to over 60% of the depth increment during the rapid increment stage, while vaporization is dominant and contributes to about 80% of the depth increment during the slow increment stage. The results reveal the material removal mechanism for single-pulse laser drilling on PEEK, which is helpful to understand the dynamic process of keyhole evolution. This not only provides a processing window for future laser drilling of PEEK but also gives a guide for the manufacturing of other polymers.

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Effect of Cutting Fluid Delivery Method on Ultrasonic Assisted Edge Trimming of Multidirectional CFRP Composites at Different Machining Conditions

Cited by 29 publications

References 21 publications

Analysis of Carbon Fiber-Reinforced Polymer Composites Delamination during Vibration Assisted Trimming using Historical Data Design

Analysis of Carbon Fiber-Reinforced Polymer Composites Delamination during Vibration Assisted Trimming using Historical Data Design

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

Hole Morphology and Keyhole Evolution during Single Pulse Laser Drilling on Polyether-Ether-Ketone (PEEK)

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