Influence of fibre orientation, tool geometry and process parameters on surface quality in milling of CFRP

Voß, Robert; Seeholzer, Lukas; Kuster, Friedrich; Wegener, Konrad

doi:10.1016/j.cirpj.2016.10.002

Cited by 101 publications

(46 citation statements)

References 23 publications

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“…In the case of conventional drilling, fibre-cutting angle changes between 0°a nd 180°. Three-dimensional drilling can be simplified, which results in a two-dimensional cutting model [25,31,91,92], and thus the three-dimensional cutting of wobble milling could be simplified as well, as shown in Fig. 18.…”

Section: Discussionmentioning

confidence: 99%

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Pereszlai

Geier

2020

Int J Adv Manuf Technol

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Due to its excellent specific mechanical properties, carbon fibre-reinforced polymer (CFRP) composite is a widely used structural material in the aerospace industry. However, this material is difficult to cut, mainly due to its inhomogeneity and anisotropic features and because of the strong wear effects of its carbon fibres. In the scope of aerospace industrial uses of this material, thousands of holes have to be machined for purposes of assembly. Nevertheless, conventional drilling technologyeven if special drilling tools are usedis only moderately able to manufacture good quality holes. Wobble milling is a novel advanced hole-making technology, which has been developed to minimize machining-induced geometrical defects like delamination or uncut fibres. The main objective of the present paper is to compare wobble milling, helical milling and conventional drilling technologies concerning unidirectional CFRPs. In addition, the kinematics of wobble milling technology is discussed in detail. In the scope of this paper, numerous machining experiments were conducted in unidirectional CFRPs: herein the impact of the type of cutting tool and of process parameters on the quality of machined holes are analysed and discussed (diameter of holes, circularity error and characteristics of uncut fibres). During these investigations, experimental data were evaluated with the help of digital image processing (DIP) and with the help of analysis of variance (ANOVA) techniques. Experimental results show that the amount of uncut fibres can significantly be minimized through the application of wobble milling technology.

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Section: Discussionmentioning

confidence: 99%

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Pereszlai

Geier

2020

Int J Adv Manuf Technol

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“…Most of the samples in which delamination was observed were milled with a cutting speed of 180 m/min, contradicting the work by NorKhairusshima 22 : the delamination rate follows an inversely proportional relation. However, it should be emphasized that delamination strongly depends on the fiber orientation and feed rate direction 24 and, as previously said, not all sample pieces were verified. Figure 11 presents the resulting burrs from titanium and carbon fiber milling.…”

Section: Figure 3 Interactions Graphs Between the Factors Over Surfamentioning

confidence: 90%

Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

2019

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This work aims to study the influence of cutting parameters (cutting speed, feed rate, cutting depth and tool cutting edge angle) regarding surface roughness and burr formation during the milling of a mixed structure comprised of titanium and carbon fiber (stack). The parameters were varied from maximum to minimum, just as the tool cutting edge angle of the insert, through a full factorial design with 32 trials. The analyses were performed by measuring the surface roughness and burr size along with metallographic analyses through optic microscopy and scanning electron microscopy. The results showed that the surface roughness was higher for carbon fiber and burr size was higher for titanium. There were a number of tests with delamination of the carbon fiber, and the best cutting parameters to minimize surface roughness and burr formation were tool cutting edge angle of 45º, a feed rate of 0.028 mm/tooth, cutting depth equal to 0.26 mm and cutting speed equal to 150 m/min.

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“…A significant effect of contact pressure was shown in relation to different fiber orientations, as well as a less significant feed and rake angle effect. Voss et al [28] performed a study to analyze the influence of tool geometry, fiber orientation and cutting parameters on the surface quality in machining CFRP. The increase of the clearance angle was found to reduce the contact area and therefore reduce the machining forces.…”

Section: Introductionmentioning

confidence: 99%

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

et al. 2019

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Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

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Influence of fibre orientation, tool geometry and process parameters on surface quality in milling of CFRP

Cited by 101 publications

References 23 publications

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

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