FE modelling of CFRP machining- prediction of the effects of cutting edge rounding

Duboust, Nicolas; Pinna, C.; Ghadbeigi, Hassan; Collis, Andrew; Ayvar-Soberanis, Sabino; Kerrigan, Kevin; Scaife, Richard J.

doi:10.1016/j.procir.2019.04.037

Cited by 13 publications

(4 citation statements)

References 12 publications

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“…The regression equation for the overall surface roughness which implements categorical effects for the surface roughness is shown in equations (1)- (4). Where CER is the cutting edge radius, FR is the feed rate and CS is the cutting speed.…”

Section: Fibre Orientation Categorical Modelmentioning

confidence: 99%

“…Previous research has shown that induced surface roughness in a milling and edge trimming operation is significantly affected by ply orientation and tool cutting edge radius (CER). [1][2][3][4][5] Cutting parameters and uncut chip thickness have additionally been shown to have a critical effect on machining induced surface quality and pitting magnitude. [6][7][8] Chen et al 9 have compiled a thorough analysis of the different types of cutting mechanism for the 0°, 45°, 90°and 135°fibre orientations, using micro textured tools in a composite milling process, and shown how fibre orientation will influence the machined surface quality.…”

Section: Introductionmentioning

confidence: 99%

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Towards intelligent CFRP composite machining: Surface analysis methods and statistical data analysis of machined fibre laminate surfaces

Duboust

Watson

Marshall

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Many carbon fibre reinforced polymer composite parts need to be edged trimmed before use to ensure both geometry and mechanical performance of the part edge matches the design intent. Measurement and control of machining induced surface damage of composite material is key to ensuring the part retains its strength and fatigue properties. Typically, the overall surface roughness of the machined face is taken to be an indicator of the amount of damage to the surface, and it is important that the measurement and prediction of surface roughness is completed reliably. It is known that the surface damage is heavily dependent on the fibre orientation of the composite and cutting tool edge condition. This research has developed a new ply-by-ply surface roughness measurement methods using optical focus variation surface analysis and image segmentation for calculating areal surface roughness parameters of a machined carbon fibre composite laminate. Machining experiments have been completed using a polycrystalline diamond edge trimming tool at increasing levels of cutting edge radius. Optical surface measurement and µ-CT scanning have been used to assess machining induced surface and sub-surface defects on individual fibre orientations. Statistical analysis has been used to assess the significance of machining parameters on Sa (arithmetic mean height of area) and Sv (areal magnitude of maximum valley depth) areal roughness parameters, on both overall roughness and ply-by-ply fibre orientations. Empirical models have been developed to predict surface roughness parameters using statistical methods. It has been shown that cutting edge degradation, fibre orientation and feed rate will significantly affect the cutting mechanism, machining induced surface defects and surface roughness parameters.

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Section: Fibre Orientation Categorical Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Towards intelligent CFRP composite machining: Surface analysis methods and statistical data analysis of machined fibre laminate surfaces

Duboust

Watson

Marshall

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

Self Cite

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show abstract

“…Some studies are using this method to assess the effect of tool wear on the machining forces of CFRPs (Carbon Fiber Reinforced Polymers). Moreover, these methods allow us to obtain useful information for developing new cutting-tool geometries for machining that can further improve the machining of these materials [31].…”

Section: Cutting Force Prediction Methodsmentioning

confidence: 99%

Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Sousa

Silva

Fecheira

et al. 2020

Sensors

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Machining processes remain an unavoidable technique in the production of high-precision parts. Tool behavior is of the utmost importance in machining productivity and costs. Tool performance can be assessed by the roughness left on the machined surfaces, as well as of the forces developed during the process. There are various techniques to determine these cutting forces, such as cutting force prediction or measurement, using dynamometers and other sensor systems. This technique has often been used by numerous researchers in this area. This paper aims to give a review of the different techniques and devices for measuring the forces developed for machining processes, allowing a quick perception of the advantages and limitations of each technique, through the literature research carried out, using recently published works.

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“…To meet critical dimensional tolerance and achieve high edge quality, milling is commonly deployed in FRTP parts manufacturing [84]. Owning to the material's anisotropy and heterogeneity, milling-induced damage such as burr formation and microstructural damage can be easily induced, severely affecting the quality and performance the machined FRTP parts [85].…”

Section: Millingmentioning

confidence: 99%

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Luo

Catalanotti

et al. 2023

Preprint

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Fibre reinforced thermoplastic polymer (FRTP) composites have been used for a wide range of engineering applications (e.g. in transport, construction, energy, etc) due to their excellent mechanical properties and ease of repair and recycling. In recent years, FRTP is increasingly deployed as an alternative to conventional thermoset carbon fibre reinforced epoxy (CF/epoxy) composites, for the purpose of reducing the carbon footprint and contributing to a sustainable manufacturing agenda. Machining of FRTP remains an indispensable process to achieve rapid parts assembly whilst meeting stringent geometric tolerances. However, due to the heterogeneous structure and high thermal sensitivity of FRTP, a range of machining-induced damages (such as matrix smearing, thermal degradation, delamination, burr and surface cavity) often occur, leading to concerns on machined parts quality and reliability. To date, composite machining studies have been mostly focused on conventional thermoset CF/epoxy and there is a lack of an up-to-date, in-depth review of the latest advancement concerning the machining of FRTP. This paper provides a state-of-the-art overview on the recent developments in FRTP machining over the past decade, with a particular emphasis on machining characteristics, damage mechanisms as well as the challenges facing such manufacturing process. The purpose is to present the composite manufacturing community with a timely update, which may guide and inspire further research and development for future FRTP manufacturing.

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FE modelling of CFRP machining- prediction of the effects of cutting edge rounding

Cited by 13 publications

References 12 publications

Towards intelligent CFRP composite machining: Surface analysis methods and statistical data analysis of machined fibre laminate surfaces

Towards intelligent CFRP composite machining: Surface analysis methods and statistical data analysis of machined fibre laminate surfaces

Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

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