Establishment of instantaneous milling force prediction model for multi-directional CFRP laminate

Ning, Haifeng; Zheng, Hualin; Yuan, Xinman

doi:10.1177/16878140211027706

Cited by 7 publications

(2 citation statements)

References 18 publications

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“…With a low clearance angle (8.4°) of the tool, both delamination and cutting force increased. The formation of delamination is consistent with the data in [ 31 ].…”

Section: Discussionsupporting

confidence: 92%

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

Knápek,

Dvořáčková,

Váňa

2023

Materials

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This study aimed to investigate the effect of the clearance angle of the milling tool on wear, cutting forces, machined edge roughness, and delamination during non-contiguous milling of carbon-fiber-reinforced plastic (CFRP) composite panels with a twill weave and 90° fiber orientation. To achieve the objective of the study, it was first necessary to design suitable tools (6 mm diameter sintered carbide shank milling cutters) with a variety of clearance angles (8.4°, 12.4°, and 16.4°) and all the machinery and measuring equipment for the research to be carried out. Furthermore, measurement and evaluation methods for cutting tool wear, cutting forces, machined edge roughness, and delamination were developed. Last but not least, the results obtained during the research were summarized and evaluated. From the experiments conducted in this study, it was found that the tool clearance angle has a significant effect on tool wear, roughness of the machined surface, and delamination of the carbon fiber composite board. The tool with a clearance angle of 8.4° wore faster than the tool with a clearance angle of 16.4°. The same trend was observed for cutting force, machined surface roughness, and delamination. In this context, it was also shown that the cutting force increased as the tool wear increased, which in turn increased surface roughness and delamination. These results are of practical significance, not only in terms of the quality of the machined surface but also in terms of time, cost, and energy savings when machining CFRP composite materials.

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“…With a low clearance angle (8.4°) of the tool, both delamination and cutting force increased. The formation of delamination is consistent with the data in [ 31 ].…”

Section: Discussionsupporting

confidence: 92%

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

Knápek,

Dvořáčková,

Váňa

2023

Materials

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show abstract

“…Thus, compared with conventional metal cutting, the removal process of CFRPs are more complicated, and damages such as fiber pull-out, burr, and matrix cracking are very likely to occur during the processing, which will have a severe impact on the service life of composite parts. [5][6][7][8] Therefore, suppressing cutting damage and improving machining quality are enormous challenges that need to be addressed in the development of CFRP machining technology.…”

Section: Introductionmentioning

confidence: 99%

Research on CFRP cutting mechanism by the micro-textured tool using macroscopic and microscopic numerical simulations

Cheng

et al. 2022

Journal of Reinforced Plastics and Composites

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Carbon fiber reinforced plastics (CFRP) composites are the most widespread advanced composite materials. Still, machining with traditional tools quickly generates defects such as high cutting forces and severe subsurface damage, while micro-textured tools can improve CFRP machining performance. Therefore, to reveal the cutting mechanism of CFRP processing by micro-textured tools and guide the tool design, macroscopic and microscopic orthogonal cutting models were established in this study, which compared and analyzed the material removal process and the indicated topography of unidirectional CFRP with different fiber orientations (0°, 45°, 90°, and 135°) by traditional tools and micro-textured tools, and the accuracy of the models was verified with experiments. Compared with traditional tools, micro-textured tools reduce cutting forces by minimizing the tool-chip contact length to reduce friction and converting the fiber failure form from crush failure to shear failure. Meanwhile, the texture on the rake face enables cutting burrs, effectively improving the surface quality of the workpiece and suppressing the depth of subsurface damage. In addition, the influence of different texture parameters on the machining quality of the workpiece was analyzed.

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Experimental study on the mechanical property of carbon fiber reinforced polymer with the combined application of digital twin and reduced order algorithm

Ji,

Wang,

Gong

et al. 2024

Polymer Composites

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Recognizing the anisotropy of mechanical property transfer between carbon fiber reinforced polymer (CFRP) layers, a unidirectional reduced‐order model (UROM) is proposed to comprehensively express the mechanical properties of each layer. A crucial focus is on effectively analyzing the real‐time mechanical properties of CFRP specimens, particularly in accurately identifying and predicting the interlaminar mechanical states of anisotropic CFRP laminated specimens. Moreover, the multi fidelity surrogate (MFS) is employed to replace the computationally intensive model, amalgamating high‐fidelity sensor data with low‐fidelity data obtained from the UROM. The UROM MFS is used to reduce the amount of data in the same layer of CFRP laminates, while preserving the characteristics between different layers and preserving the interlaminar information of CFRP laminates. Finally, the stress prediction results of the UROM MFS and the unreduced MFS model were compared and analyzed. The real‐time response speed of the u‐ROM MFS digital twin (DT) model was increased by 658%. The UROM MFS DT model effectively captures the mechanical properties of each layer of CFRP laminates, enables quick calculation of model parameters, and provides accurate predictions.Highlights First, the interlayer mechanical property of CFRP is analyzed with the combined application of experimental data, DT model, and UROM MFS. Second, MFS is employed to merge high‐fidelity sensor data of CFPR laminate with low‐fidelity data obtained from UROM. Third, the digital twin framework for CFPR laminate with high response speed and calculation accuracy is proposed.

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Establishment of instantaneous milling force prediction model for multi-directional CFRP laminate

Cited by 7 publications

References 18 publications

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

Research on CFRP cutting mechanism by the micro-textured tool using macroscopic and microscopic numerical simulations

Experimental study on the mechanical property of carbon fiber reinforced polymer with the combined application of digital twin and reduced order algorithm

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