Machining of Thermoplastic Composites

Ahmad, Furkan; Manral, Ankit; Bajpai, Pramendra Kumar

doi:10.1007/978-981-13-6019-0_8

Cited by 12 publications

(12 citation statements)

References 39 publications

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“…In recent years, thermoplastics are obtaining a lot of importance as a potential matrix material in polymer‐based composites due to their superior performance maintained at higher temperatures. [ 1 ] This leads to the fact that the thermoplastics are gaining popularity in replacement of conventional thermosets because of their recyclability, better curing property, and appreciable toughness. Thermoplastic composites are featured by many advantages in comparison with thermoset composites, such as high toughness, high impact resistance, short molding cycle, high production efficiency, easy to repair and reuse of waste materials.…”

Section: Introductionmentioning

confidence: 99%

“…Out of all manufacturing operations, drilling is the most practical cutting process in order to create holes for assembling the fibrous components into useful products. [1,7] The machining behavior of thermoplastic composites differs from that of thermoset composites due to their disparate natures. Thermoplastics can be easily melted compared with the thermosets due to linear chains of molecules connected by secondary bonds which are easier to break.…”

Section: Introductionmentioning

confidence: 99%

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On the machining behavior of carbon fiber reinforced polyimide and PEEK thermoplastic composites

Huang

Davim

et al. 2020

Polymer Composites

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Polyimide (PI) and polyetheretherketone (PEEK) are superior high‐performance thermoplastics being extensively used in the fields of fiber‐reinforced polymer composites. However, there is very limited literature addressing the machining behavior of the PI and PEEK composites. The present paper aims to conduct a comparative study into the machining characteristics of these two representative high‐performance thermoplastic matrix composites under varying cutting conditions. Machinability aspects of the carbon/PI and carbon/PEEK thermoplastic composites were evaluated in terms of drilling forces, machining temperatures, delamination damage, surface morphologies, hole dimensional accuracy and tool wear. The results indicate that the carbon/PEEK composites generally show a much poorer machinability than the carbon/PI composites in terms of higher drilling forces, higher cutting temperatures, larger delamination extents and excessive tool wear. Since the carbon/PEEK composites exhibit certain ductility leading to the continuous chip formation, the cut hole surface morphologies and dimensional accuracy are much better than those gained in the carbon/PI composites. Both the cutting speed and the feed rate affect significantly the drilling forces and the resulting delamination damage. The fundamental wear mechanisms of drilling carbon/PI composites are abrasion wear in the form of edge rounding and slight chip adhesion, while for the carbon/PEEK composites, they are abrasion, serious chip adhesion because of the high drilling temperatures promoted at the drill‐work interface and catastrophic failures of coating peeling and edge fracture.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

On the machining behavior of carbon fiber reinforced polyimide and PEEK thermoplastic composites

Huang

Davim

et al. 2020

Polymer Composites

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“…Unconventional methods such as abrasive water jet drilling (AWJ), ultrasonic machining (USM), and laser beam machining (LBM), have also been used recently. AWJ has the limitations of high operation cost, abrasive slurry collection, and low material removal rate, despite producing holes with small thermal damage [ 16 , 17 ]. A low material removal rate and tool wear also limit the utilization of USM [ 18 ].…”

Section: Introductionmentioning

confidence: 99%

“…It is easy to realize the high precision and automation of drilling. Compared with other processing technologies, it imparts many advantages including the processing of micro-holes and thin kerf width, no toolwear or frequent replacement of tools, higher drilling speed, and absence of drilling force, abrasives, and liquid media [ 6 , 16 , 22 ]. With these advantages, laser drilling has increasingly been used in the processing of PEEK and other polymers.…”

Section: Introductionmentioning

confidence: 99%

Hole Morphology and Keyhole Evolution during Single Pulse Laser Drilling on Polyether-Ether-Ketone (PEEK)

Zhang

Tian

et al. 2022

Materials

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Polyether-ether-ketone (PEEK), with its superior mechanical, chemical, and thermal properties, as well as high biocompatibility, has been used in aerospace, electronics, and biomedical applications. In this paper, a large number of experiments of single-pulse laser drilling on PEEK were performed to analyze the hole morphology and keyhole evolution, which were characterized by an optical microscope, charge-coupled device (CCD), and high-speed camera. A novel method is proposed to observe and measure the dimension of the processed hole rapidly right after laser drilling for special polymer materials with wear-resistance and non-conductivity. Morphological characteristics of holes are presented to illustrate the effect of pulse width and peak power on hole depth, hole diameter, and aspect-ratio. The obtained maximum drilling depth was 7.06 mm, and the maximum aspect-ratio was 23. In situ observations of the dynamic process of laser drilling, including the keyhole evolution together with ejection and vaporization behavior, were also carried out. The keyhole evolution process can be divided into three stages: rapid increment stage (0–2 ms) at a rate of 2.1 m/s, slow increment stage (2–4 ms) at a rate of 0.3 m/s, and stable stage (>4 ms). Moreover, the variation of dimensionless laser power density with the increase in pulse width was calculated. The calculated maximum drilling depth based on energy balance was compared with the experimental depth. It is proven that the laser–PEEK interaction is mainly influenced by a photothermal effect. Ejection is the dominant material-removal mechanism and contributes to over 60% of the depth increment during the rapid increment stage, while vaporization is dominant and contributes to about 80% of the depth increment during the slow increment stage. The results reveal the material removal mechanism for single-pulse laser drilling on PEEK, which is helpful to understand the dynamic process of keyhole evolution. This not only provides a processing window for future laser drilling of PEEK but also gives a guide for the manufacturing of other polymers.

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“…Due to the abrasive nature of the reinforcement and the low cohesion between laments and matrix due to the low viscosity of the thermoplastic material can generate great di culties in the machining of these materials [10]. Also, the characteristic anisotropy of these materials means that each orientation of the material behaves differently when using cutting geometries, which can lead to defects such as delamination or low surface quality [11].…”

Section: Introductionmentioning

confidence: 99%

Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions

Sambruno

Bañon

Salguero

et al. 2021

Int J Adv Manuf Technol

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The application of Carbon Fiber Reinforced ThermoPlastic matrix composites (CFRTP) is constantly increasing in various industrial sectors. Their mechanical properties and advantages compared to thermoset composite materials make them very important materials. Nevertheless, CFRTP machining generates a current problem due to the anisotropy of these materials, the di culty of impregnation of the reinforcement in the matrix and its low melting temperature. For this reason, the study of conventional operations such as milling to achieve geometries with a good surface quality and reduced cosmetic defects is a line of research of great interest. In this article, a comparison of ve cutting tools with different geometries has been made in CFRTP milling. The surface quality and the formation of visual defects such as ber pull-out have been evaluated for each tool and combination of cutting parameters. In this sense, 16.42 µm in terms of Rz is the minimum average value for the complete experiment obtained for a conventional tool (Tool A). However, surface qualities in terms of Rz close to 20 µm and minimum cosmetic defects have been obtained with a hybrid tool (Tool C) with -10° helix angle and 8 teeth with a combination of cutting parameters of 0.07 mm/tooth and 3000 rpm, being the most complete tool of the experiment.

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Machining of Thermoplastic Composites

Cited by 12 publications

References 39 publications

On the machining behavior of carbon fiber reinforced polyimide and PEEK thermoplastic composites

On the machining behavior of carbon fiber reinforced polyimide and PEEK thermoplastic composites

Hole Morphology and Keyhole Evolution during Single Pulse Laser Drilling on Polyether-Ether-Ketone (PEEK)

Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions

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