On the Surface Quality of CFRTP/Steel Hybrid Structures Machined by AWJM

Abstract

The joining of dissimilar materials in a hybrid structure is a line of research of great interest at present. Nevertheless, the machining of materials with different machinability requires specific processes capable of minimizing defectology in both materials and achieving a correct surface finish in terms of functional performance. In this article, abrasive water jet machining of a hybrid carbon fiber-reinforced thermoplastics (CFRTP)/Steel structure and the generated surface finish are studied. A parametric study in two stacking configurations (CFRTP/Steel and Steel/CFRTP) has been established in order to determine the range of cutting parameters that generates the lowest values in terms of arithmetic mean roughness (Ra) and maximum profile height (Rz). The percentage contribution of each cutting parameter has been identified through an ANOVA analysis for each material and stacking configuration. A combination of 420 MPa hydraulic pressure with an abrasive mass flow of 385 g/min and a travel speed of 50 mm/min offers the lowest Ra and Rz values in the CFRTP/Steel configuration. The stacking order is a determining factor, obtaining a better surface quality in a CFRTP/Steel stack. Finally, a series of contour diagrams relating surface quality to machining conditions have been obtained.

A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials

“…From an environmental point of view, this process has high efficiency by using water at high pressure, that can be reused later, reducing its negative impact on the environment. Compared to conventional technologies, there is no physical tool, and there is much less wear on auxiliary elements, reducing process costs as it can be used over a wide range of materials with different machinability at the same time [19]. In addition, metalworking fluids (MWF) are not required [24].…”

“…Hybrid Structure: This is the nomenclature that has begun to be used in the last few years and that will be adopted throughout this research work. It refers to the union of a metallic alloy to a polymeric matrix composite material, which can be joined by means of an adhesive or thermal bond [19].…”

Metal Machining—Recent Advances, Applications, and Challenges

“…Based on the obtained results, models that allow for the prediction of macro dimensional deviations as a function of machining parameters were presented. Bañon et al [41] carried out a quality study of the cut surface in structures composed of different materials. In that case, the abrasive waterjet cutting of a mixed structure of CFRTP (carbon fiber-reinforced thermo-plastic) with steel was studied, which presented quite different behaviors under the same cutting conditions.…”

Study of the EDM Process of Bimetallic Materials Using a Composite Electrode Tool

“…Technological difficulties arise in terms of heat removal and thermal conductivity in the cutting zone. Traditional cutting is not possible [17][18][19][20].…”