Machinability analysis on helical milling of carbon fiber reinforced polymer

Wang, Haiyan; Qin, Xuda; Li, Hao

doi:10.1299/jamdsm.2015jamdsm0057

Cited by 11 publications

(5 citation statements)

References 13 publications

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“…In a mold manufacturing it is estimated that 65% of the costs are due to finishing and semi-finishing processes by machining [2,3]. Between these processes, hole-making spends from 25% to 50% of the cycle time and 33% of the total number of operations, requesting reliability due to the high added value to the part being processed [4,5].…”

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confidence: 99%

“…The maximum axial depth of cut (ap * ) is mathematically dependent of the feed velocities components in axial and tangential directions [14]. Firstly, the helix angle (α) can be expressed through Equation 5 and, subsequently, ap * , which is the helical pitch, in [mm/rev], is calculated through the Equation 6, considering the helix angle and the length of the circular path (π×Dh). By manipulating this expression considering Equations 1-4, ap * may be defined with regard to fza and fzt to understand the effect of these portions of cut related to axial and peripheral cut, respectively [16].…”

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Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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Helical milling is a hole-making process which has been applied in hardened materials. Due to the difficulties on achieving high-quality boreholes in these materials, the influence of noise factors, and multi-quality performance outcomes, this work aims the multi-objective robust design of hole quality on AISI H13 hardened steel. Experiments were carried out through a central composite design considering process and noise factors. The process factors were the axial and tangential feed per tooth of the helix, and the cutting velocity. The noise factors considered were the tool overhang length, the material hardness and the borehole height of measurement. Response models were obtained through response surface methodology for roughness and roundness outcomes. The models presented good explanation of data variability and good prediction capability. Mean and variance models were derived through robust parameter design for all responses. Similarity analysis through cluster analysis was realised, and average surface roughness and total roundness were selected to multi-objective optimisation. Mean square error optimisation was performed to achieve bias and variance minimization. Multi-objective optimisation through normalized normal constraint was performed to achieve a robust Pareto set for the hole quality outcomes. The normalized normal constraint optimisation results outperformed the results of other methods in terms of evenness of the Pareto solutions and number of Pareto optimal solutions. The most compromise solution was selected considering the lowest Euclidian distance to the utopia point in the normalized space. Individual and moving range control charts were used to confirm the robustness achievement with regard to noise factors in the most compromise Pareto optimal solution. The methodology applied for robust modelling and optimisation of helical milling of AISI H13 hardened steel was confirmed and may be applied to other manufacturing processes. KeywordsHelical milling; AISI H13 hardened steel; Multi-objective robust optimization; Robust parameter design; Normalized normal constraint method. R 2 coefficient of determinationRadj 2 adjusted coefficient of determination Radj 2 prediction coefficient of determination

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confidence: 99%

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Pereira

Silva

Lauro

et al. 2019

Applied Soft Computing

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“…They stated a similar conclusion for the aluminum alloy, where the force was 50% smaller using a coated tool in comparison to drilling with a non-coated tool. Wang [ 34 ] showed that the cutting force increases with increasing feed rate but depends on the cutting speed. Examining the results of cutting forces, it can be noted that for both types of tools for f z = 0.04 mm/min and for the non-coated tool at f z = 0.12 mm/min, the cutting forces increased with an increase in the cutting speed.…”

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confidence: 99%

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

et al. 2020

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In this study, the effect of cutting parameters on the quality of an Al/CFRP sandwich structure (aluminium alloy–carbon fibre reinforced polymer) after milling with uncoated and TiAlN-coated tools was examined. The results of the cutting force were also investigated. The research was conducted in a VMC 800 HS vertical machining centre with a variable cutting speed and feed. The milling process was carried out using a non-coated, two-blade carbide milling cutter with a 35° helix angle and an analogous tool with a TiAlN coating. The surface quality was characterised in terms of the height deviation, which is one of the shape deviations after machining hybrid materials. The research showed that the maximum (77.60 µm) and minimum (1.78 µm) values of the height deviations were obtained using the tool with a TiAlN coating. It was found that the tested factors had significant effects on the height deviation, where the feed had the greatest influence and the cutting speed had the lowest influence on the surface quality. The tested factors were not statistically significant in terms of the cutting force.

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“…It was observed that the best machining quality was obtained with the combination of high cutting speed, low feed rate and effective chip thickness. In another study, Wang et al [23] worked on the delamination damage occurring during the unidirectional and multidirectional helical milling of CFRP composites, and reported that delamination was observed on the machined edges, arising from tool wear and resulting in inadequate machining quality. They found that adequate machining performance was obtained with a sharp cutting tool, which also prevented delamination failure.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Tool Wear and Delamination in Milling CFRPs with TiAlN- and TiN-Coated Tools

et al. 2020

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Carbon fiber-reinforced polymers (CFRPs) have very good mechanical properties, such as extremely high tensile strength/weight ratios, tensile modulus/weight ratios, and high strengths. CFRP composites need to be machined with a suitable cutting tool; otherwise, the machining quality may be reduced, and failures often occur. However, as a result of the high hardness and low thermal conductivity of CFRPs, the cutting tools used in the milling process of these materials complete their lifetime in a short cycle, due to especially abrasive wear and related failure mechanisms. As a result of tool wear, some problems, such as delamination, fiber breakage, uncut fiber and thermal damage, emerge in CFRP composite under working conditions. As one of the main failure mechanisms emerging in the milling of CFRPs, delamination is primarily affected by the cutting tool material and geometry, machining parameters, and the dynamic loads arising during the machining process. Dynamic loads can lead to the breakage and/or wear of cutting tools in the milling of difficult-to-machine CFRPs. The present research was carried out to understand the influence of different machining parameters on tool abrasion, and the work piece damage mechanisms during CFRP milling are experimentally investigated. For this purpose, cutting tests were carried out using a (Physical Vapor Deposition) PVD-coated single layer TiAlN and TiN carbide tool, and the abrasion behavior of the coated tool was investigated under dry machining. To understand the wear process, scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) was used. As a result of the experiments, it was determined that the hard and abrasive structure of the carbon fibers caused flank wear on TiAlN- and TiN-coated cutting tools. The best machining parameters in terms of the delamination damage of the CFRP composite were obtained at high cutting speeds and low feed rates. It was found that the higher wear values were observed at the TiAlN-coated tool, at the feed rate of 0.05 mm/tooth.

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Machinability analysis on helical milling of carbon fiber reinforced polymer

Cited by 11 publications

References 13 publications

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Multi-objective robust design of helical milling hole quality on AISI H13 hardened steel by normalized normal constraint coupled with robust parameter design

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

Experimental Study on Tool Wear and Delamination in Milling CFRPs with TiAlN- and TiN-Coated Tools

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