Milling force prediction model development for CFRP multidirectional laminates and segmented specific cutting energy analysis

Ning, Haifeng; Zheng, Hualin; Zhang, Shigui; Yuan, Xinman

doi:10.1007/s00170-021-06690-7

Cited by 14 publications

(3 citation statements)

References 17 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Delamination will occur when F z is greater than the adhesion between the fiber and the matrix. F z is the main cause of surface delamination; the cutting force first increases, then decreases, and finally increases with the FCA from 0° to 180° [50]. The cutting force increases with the feed rate and radial cutting depth [51].…”

Section: Delaminationmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

View full text Add to dashboard Cite

Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

show abstract

Section: Delaminationmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

View full text Add to dashboard Cite

show abstract

“…Since the linear velocity of the tool is much greater than its feed rate in the actual milling of the CFRP, the chip-thickness changes are very limited [ 31 ]. Therefore, the instantaneous chip can be converted into an equivalent chip with uniform thickness, as shown in Figure 3 b.…”

Section: Preparation Workmentioning

confidence: 99%

Study on Milling Force and Surface Quality during Slot Milling of Plain-Woven CFRP with PCD Tools

Wang

2022

Materials

View full text Add to dashboard Cite

Carbon-fiber-reinforced polymers (CFRPs) have been widely used in many industrial fields, such as automobile, aerospace and so on, because of their excellent mechanical properties. However, due to their anisotropy and inhomogeneity, machining CFRPs is a great challenge. In this paper, the slot milling of a plain-woven CFRP with PCD tools is carried out, and the effects of cutting parameters and tool rake angle on cutting force and surface roughness are studied. The results show that the 4° rake angle PCD tool has smaller cutting force than the 0° rake angle PCD tool, but the effect of rake angle on surface roughness is not significant. The concept of equivalent cutting area is introduced to study the variation law of cutting force and surface roughness. It is found that the cutting force and surface roughness increase with the increase in equivalent cutting area, and decrease with the decrease in equivalent cutting area. The removal mechanism of surface materials under different equivalent cutting areas is different, which leads to the difference in surface roughness. Finally, the causes of delamination on the top layer after milling are explained.

show abstract

“…Through the above equivalent method, we can regard the milling process as orthogonal plane cutting. So the instantaneous cutting area can be written as [24]:…”

Section: Equivalent Cutting Areamentioning

confidence: 99%

Study on cutting force and surface roughness during slot milling plain woven CFRP

Xu¹,

Wang

2022

Preprint

View full text Add to dashboard Cite

Due to the anisotropy and poor heat dissipation of carbon fiber reinforced plastics (CFRP), it is easy to produce high cutting force in the machining process, which makes the machined surface quality worse. This paper studies the effects of spindle speed, feed rate and cutting depth on milling force and surface roughness during slot milling plain-woven CFRP by Taguchi orthogonal experimental design. Convert the instantaneous chip thickness into equivalent cutting area, and the cutting force and surface roughness increase with the increase of equivalent cutting area and decrease with the decrease of equivalent cutting area. The surface material removal mechanism of PCD tool under different equivalent cutting areas is analyzed. The variance analysis of cutting force and surface roughness produced by PCD tool and CVD diamond coated end mill is carried out. It is found that the spindle speed has the most significant effect on cutting force and surface roughness. In addition, it is also found that burrs will occur when the tool rotation angle φ is between 60°-90°and delamination defects occur in the range of 150°-180°.

show abstract

Milling force prediction model development for CFRP multidirectional laminates and segmented specific cutting energy analysis

Cited by 14 publications

References 17 publications

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Study on Milling Force and Surface Quality during Slot Milling of Plain-Woven CFRP with PCD Tools

Study on cutting force and surface roughness during slot milling plain woven CFRP

Contact Info

Product

Resources

About