Effects of Grinding Process Parameters and Coolants on the Grindability of GFRP Laminates

Abstract

Grinding is one of the mandatory methods for fabrication of precise glass fibre reinforced plastic (GFRP) parts. In this work, grinding studies were carried out on GFRP using a CBN wheel. The grinding process was performed at different cutting speeds, feed rates and depth of cuts. Grinding performance was evaluated by measuring forces and surface roughness of the ground GFRP composite laminate material. The effects of coolants in grinding the composite laminate material were investigated. Test results showed that in most cases, dry grinding achieved the greatest material removal rate and the lowest surface area roughness (Sa). Higher speed tends to produce better surface finish in dry grinding. Surface area roughness produced in wet grinding shows random and drastic variations. Surfaces ground in synthetic coolant show clean, hard and smooth matrix, and are in general better quality than those ground with emulsion coolant. Optical and electron microscopy was used to evaluate the grinding mechanism of GFRP laminate material. Surface profile waviness is the predominating factor contributing to surface area roughness over surface peaks and valleys.

RETRACTED: A pure thermal model to evaluate heat-affected zone when milling E-glass fiber-reinforced polyester composites

“…is commonly pointed out as a main obstacle prohibiting the good control of material removal process. [1][2][3][4] Despite significant research that has been conducted on mechanical response of polymeric composites within the last decades, their thermal behavior still remains under discussed and challenging. The thermomechanical behavior owing to tool-material contact is widely considered responsible for the most physical phenomena generated throughout the machining process.…”

“…Chockalingam et al 2,18 evaluated the effects of tool abrasive types on force and roughness when grinding GFRP at varying conditions. Performances of cubic boron nitride (CBN) abrasives was specially investigated and compared to alumina (Al 2 O 3 ).…”

Effects of Abrasive Types on Grinding of Chopped Strand Mat Glass Fiber-Reinforced Polymer Composite Laminates

“…The workpiece was fixed on the dynamometer platform inside the machining centre as shown in Figure 1. The grinding process was carried out with an alumina (OA46QV) and a CBN (BA46QV) profile mounted wheel of 25 mm diameter x 19 mm length x 6 mm mandrel, respectively (Chockalingam et al, 2013). Composite laminate made of 450 g/m 2 R-glass, chopped strand mat (CSM) fiber reinforced in unsaturated polyester (Reesol P9509) polymer has been used in this investigation.…”

Feasibility studies on wet grinding of carbon fibre reinforced epoxy polymer at minimum defect condition via eccentric sleeve grinding

“…Chockalingam et al, 20 investigated the effect of coolant on parameters such as surface roughness and cutting forces while grinding chopped strand mat glass fibre reinforced polymer (GFRP) laminates and found the use of coolant to be beneficial. Further, Chockalingam et al, 21 inspected the influence of different categories of cutting fluids on surface integrity of GFRP laminates by varying the cutting parameters. Sasahara et al, 22 explored the possibility of using an internal cooling mechanism in a grinding wheel while grinding carbon fibre reinforced plastic composites.…”