Abstract:Carbon fibre-reinforced polymer composites are finding increased applications in the field of automotive manufacture and aircraft industries due to their appreciative combination of high strength and low weight. The machining of these composites with economically viable and high part qualities requires enhancement in machining strategies. Delamination and surface roughness are the undesirable geometrical defects inherent in abrasive jet machining of layered polymer composites. This investigation focuses on the… Show more
“…Kerf angle produced by threaded nozzle was lower than that of the generated by without threaded nozzle. Madhu and Balasubramanian [69] further extended their previous work at the same machining condition. They found that internal thread within the nozzle showed 29% less entry delamination and 13% less exit delamination compared to without threaded nozzle.…”
Section: Effect Of Nozzle Geometry and Sizementioning
Fiber-reinforced composites have established as a high-performance composite of modern advanced structures in various sectors such as automotive, aerospace, and marine industries. Non-conventional machining processes are preferred for the ease of manufacturing operations, which incorporates the machining of high strength and anisotropic material. Non-conventional manufacturing processes produce complicated shaped profiles and better surface characteristics. Abrasive water jet (AWJ) machining is an emerging technology that offers an excellent alternative among the various advanced machining processes due to its process capabilities and excellent machining quality. AWJ machining has fascinated immense attention in the fields of fiber-reinforced composite materials to produce intricate industrial components and attracted the researchers and production industries. It has become well-known in all key areas of researches. Over the past 30 years, lots of research work has been carried out to describe the machining performances among the studied process parameters. This paper reviews the research progresses and integrated functions of AWJ machining in terms of mechanism and machining performances, which includes aspects such as mathematical modeling and optimization. AWJ machining procedure and performance capability are reviewed and depicted in detail. Also, a comprehensive conclusion of this review, along with future perspective, is explored subsequently. The current review work will help future researchers for the proper selection of different FRP material composite compositions and AWJ machining parameters to achieve better performances. The collection of this review literature will also support the production operations in the future.
“…Kerf angle produced by threaded nozzle was lower than that of the generated by without threaded nozzle. Madhu and Balasubramanian [69] further extended their previous work at the same machining condition. They found that internal thread within the nozzle showed 29% less entry delamination and 13% less exit delamination compared to without threaded nozzle.…”
Section: Effect Of Nozzle Geometry and Sizementioning
Fiber-reinforced composites have established as a high-performance composite of modern advanced structures in various sectors such as automotive, aerospace, and marine industries. Non-conventional machining processes are preferred for the ease of manufacturing operations, which incorporates the machining of high strength and anisotropic material. Non-conventional manufacturing processes produce complicated shaped profiles and better surface characteristics. Abrasive water jet (AWJ) machining is an emerging technology that offers an excellent alternative among the various advanced machining processes due to its process capabilities and excellent machining quality. AWJ machining has fascinated immense attention in the fields of fiber-reinforced composite materials to produce intricate industrial components and attracted the researchers and production industries. It has become well-known in all key areas of researches. Over the past 30 years, lots of research work has been carried out to describe the machining performances among the studied process parameters. This paper reviews the research progresses and integrated functions of AWJ machining in terms of mechanism and machining performances, which includes aspects such as mathematical modeling and optimization. AWJ machining procedure and performance capability are reviewed and depicted in detail. Also, a comprehensive conclusion of this review, along with future perspective, is explored subsequently. The current review work will help future researchers for the proper selection of different FRP material composite compositions and AWJ machining parameters to achieve better performances. The collection of this review literature will also support the production operations in the future.
“…The size of the abrasive particles has a significant effect on surface roughness and the specific wear rate of abrasives. 59 In general, the specific wear rate decreases with decreasing particle size and hardness. 37,60 Singh et al 61 analyze the effect of abrasive size on wear rate.Figure 10.Effect of polishing abrasives made by pearlite grains: (a) MRR and (b) Percentages of thickness losses.…”
The manufacture of abrasives based on waste grains of pumice stones and pearlites represents the aim of this work is to minimize both the cost of the product and to recover industrial waste that harms the environment. We also used a non-woven based on cellulosic fibers as reinforcement and three types of resins (polyurethane, acrylic, and polyester). Obtaining these products is designed by two processes (by spraying and by coating). The effect of the manufacturing process, the type and size of the grains on the abrasive wear of denim fabrics, the material removal rate (MRR), and the surface morphologies obtained were quantitatively evaluated. A chemical analysis (FTIR) and a thermal analysis were carried out (ATG/DSC). Scanning electron microscopy (SEM) was performed to see the appearance of these grains and measure their diameter. Inductively Coupled Plasma Mass Spectrometry (ICP/MS) analyses show that pumice grains contain more calcium atoms than pearlite grains. The different abrasion grains were compared according to their polishing effect. We note that the abrasive manufacturing process, type, and size of abrasive particles affect the MRR. Pumice grits allow for deeper polishing compared to other grits.
“…The concept of the delamination factor (i.e. the ratio of the maximum diameter D max in the damage zone to the hole diameter D ), namely, the conventional delamination factor (F d ) helps easy analysis and comparison of the degree of delamination in drilling CFRP composite laminates (Balasubramanian and Madhu, 2018).…”
Purpose
The purpose of this study is for solving many issues in production that includes processing of complex-shaped profile, machining of high-strength materials, good surface finish with high-level precision and minimization of waste. Among the various advanced machining processes, abrasive jet machining (AJM) is one of the non-traditional machining techniques used for various applications such as polishing, deburring and hole making. Hence, an overview of the investigations done on carbon fiber-reinforced polymer (CFRP) and glass fiber-reinforced polymer (GRFP) composites becomes important.
Design/methodology/approach
Discussion on various approaches to AJM, the effect of process parameters on the glass fiber and carbon fiber polymeric composites are presented. Kerf characteristics, surface roughness and various nozzle design were also discussed.
Findings
It was observed that abrasive jet pressure, stand-off distance, traverse rate, abrasive size, nozzle diameter, angle of attack are the significant process parameters which affect the machining time, material removal rate, top kerf, bottom kerf and kerf angle. When the particle size is maximum, the increased kinetic energy of the particle improves the penetration depth on the CFRP surface. As the abrasive jet pressure is increased, the cutting process is enabled without severe jet deflection which in turn minimizes the waviness pattern, resulting in a decrease of the surface roughness.
Research limitations/implications
The review is limited to glass fiber and carbon fiber polymeric composites.
Practical implications
In many applications, the use of composite has gained wide acceptance. Hence, machining of the composite need for the study also has gained wide acceptance.
Social implications
The usage of composites reduces the usage of very costly materials of high density. The cost of the material also comes down.
Originality/value
This paper is a comprehensive review of machining composite with abrasive jet. The paper covers in detail about machining of only GFRP and CFRP composites with various nozzle designs, unlike many studies which has focused widely on general AJM of various materials.
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