Modeling of cutting forces in helical milling of unidirectional CFRP considering carbon fiber fracture

Zhang, Shun; Jiao, Feng; Wang, Xue; Niu, Ying

doi:10.1016/j.jmapro.2021.06.058

Cited by 35 publications

(11 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Different strategies and methods have been studied to improve the milling performance, typically in respect to the delamination issue [ 43 , 44 ]. Model analysis has also been used to include tool wear and milling forces in order to better master the process parameters [ 45 , 46 , 47 ]. The milling process parameters can also be specifically defined for a robotic arm implementation.…”

Section: Resultsmentioning

confidence: 99%

Structural Potting of Large Aeronautic Honeycomb Panels: End-Effector Design and Test for Automated Manufacturing

2022

View full text Add to dashboard Cite

Structural potting is used to prepare honeycomb panels to fix metallic elements, typical in aircraft doors. In this paper, a full procedure for structural potting using robotic arms is presented for the first time. Automating this procedure requires the integration of, first, machining operations to remove the skin layers and prepare the potting points and, then, resin injection into the honeycomb cells. The paper describes the design, prototyping, and testing of specific end-effectors. Different end-effectors were explored to ensure efficient injection. The results obtained with the prototypes show that the potting quality is adequate to accomplish the required process checks for industrial manufacturing. The injection process time can be reduced by a factor greater than 3.5, together with the extra assets associated with the automation of complex tasks. Therefore, structural potting automation is demonstrated to be feasible with the end-effectors proposed for milling and injection, which are ready for use with conventional robotic arms in manufacturing lines.

show abstract

Section: Resultsmentioning

confidence: 99%

Structural Potting of Large Aeronautic Honeycomb Panels: End-Effector Design and Test for Automated Manufacturing

2022

View full text Add to dashboard Cite

show abstract

“…The magnitude and uctuation of cutting force directly re ect the machining state and affect the surface quality [21,22]. In the hole processing on CFRP, the cutting force directly affects the hole quality, which is the main factor causing the material delamination around the hole wall, the tearing of the entrance and exit of the hole, the burr and other major defects [23].…”

Section: Cutting Forcementioning

confidence: 99%

Helical milling for making holes on carbon fiber-reinforced polymer

Cheng

Yan³

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Carbon ber reinforced polymer (CFRP) is widely used in various elds due to its excellent properties.However, machining defects such as delamination and burr are still the key issues constraining highquality hole making on CFRP. This research takes the helical milling process to make holes on CFRP and two kinds of cutting conditions (dry cutting and jet cold air assisted cutting) are explored. Tool wear, cutting force, delamination and surface morphology are taken as the main indices to be analyzed. The in uences of key cutting parameters (spindle speed n, axial feed per tooth f za and pitch a p ) on cutting force and delamination are investigated and optimized. It turns out that the jet cold air condition is more suitable for helical milling of holes on CFRP with better qualities. The holes with smaller delamination factor and smoother surface are successfully fabricated based on the optimized cutting parameters.

show abstract

“…Due to the flexible kinematics of the tool, helical milling mainly removes material through side edges, which reduces cutting temperature, cutting force and solves the problem of interlayer delamination of composite materials and achieve better surface quality [12]. The side edges of the milling cutter are highly susceptible to wear when applied to high-speed machining [13][14].…”

Section: Introductionmentioning

confidence: 99%

“…motion equation of end mill center point OC in the coordinate system OWXWYW during LFTVAHM is shown in Eq (14)…”

mentioning

confidence: 99%

Experimental research on new hole-making method assisted with asynchronous mixed frequency vibration in TiBw/TC4 composites

Zhou

Feng

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

With the gradual promotion and the application of difficult-to-machine materials such as titanium matrix composites in the aerospace field, high-quality hole-making technology has become a major demand in aviation manufacturing. In order to improve the hole-making quality of TiBw/TC4 composites, asynchronous mixed frequency vibration assisted hole-making (AMFVAHM) method is proposed. The process consists of two steps which are base hole drilling assisted with ultrasonic vibration (UVAD) and hole expansion by helical milling assisted with low-frequency torsional vibration (LFTVAHM). Based on this process, the cutting trajectory modeling is established, and the hole-making experiment on TiBw/TC4 composites is conducted. The experimental data shows that the maximum XY-plane average milling force decreases by 30.96 % and the maximum axial average milling force decreases by 24.49 % compared with conventional helical milling (HM) when the torsional vibration frequency and the milling frequency are the same in LFTVAHM. The hole-making experiment shows that AMFVAHM can reduce the chip size, tool wear and some other defects such as entrance/exit burrs, scratches and fractures of the hole wall. Comparing with HM and UVAD, the verticality of hole wall increases by 71.43 % and 86.21 %, the inlet damage decreases by 27.98 % and 31.60 %, the outlet damage decreases by 2.80 % and 14.47 %, the hole wall roughness (Ra) decreases by 36.29 % and 63.43 %, and the maximum white layer thickness decreases by 19.99 % and 67.66 %. Meanwhile, AMFVAHM process not only reduces the cutting force and cutting temperature, but also improves the hole-making quality due to the fretting friction effect of LFTVAHM in secondary hole expansion, which meets the need of high-quality hole-making of difficult-to-machine materials in practical engineering applications.

show abstract

Modeling of cutting forces in helical milling of unidirectional CFRP considering carbon fiber fracture

Cited by 35 publications

References 21 publications

Structural Potting of Large Aeronautic Honeycomb Panels: End-Effector Design and Test for Automated Manufacturing

Structural Potting of Large Aeronautic Honeycomb Panels: End-Effector Design and Test for Automated Manufacturing

Helical milling for making holes on carbon fiber-reinforced polymer

Experimental research on new hole-making method assisted with asynchronous mixed frequency vibration in TiBw/TC4 composites

Contact Info

Product

Resources

About