Optimal milling conditions for carbon/epoxy composite material using damage and vibration analysis

Chibane, Hicham; Morandeau, Antoine; Serra, Roger; Bouchou, Abdelhake; Leroy, René

doi:10.1007/s00170-013-4903-3

Cited by 26 publications

(22 citation statements)

References 22 publications

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“…We consider a turning operation on an experimental basis for the validation of the developed and implemented algorithm, Table 1 are determined statistically by design of experiments [6][7][8][9][10][11][12][13].…”

Section: Application To the Turning Operation Casementioning

confidence: 99%

“…Numerous works have been published [1][2][3][4][5]. However, almost all of these works rely on methods and classical optimization strategies such as nonlinear programming [6], meta-heuristics method [7,8], and methods of experiments design [9]. This is usually partial optimizations [10], for the reduction of manufacturing cost [11], the reduction of total machining time [12], or again both simultaneously [13,14], which were effectively applied on an industrial scale, but without taking into account the reliability or robustness of optima.…”

Section: Introductionmentioning

confidence: 99%

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Efficient genetic algorithm for multi-objective robust optimization of machining parameters with taking into account uncertainties

Sahali

Belaidi²,

Serra³

2014

Int J Adv Manuf Technol

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The respect of the machined piece quality and productivity is closely related to the mastery of uncertain factors. Indeed, the efficient solutions obtained from the machining parameter optimization based on classical methods are assigned of uncertain deviations which affect the cutting process. In the present paper, we propose multi-and monoobjective optimization approach of parameter turning with taking into account both production constraints related to piece quality, to machine power, or to tool life, than uncertainty factors related to the tool wear and to piece geometry defaults. To this end, we developed and implemented an efficient genetic algorithm, based on an evaluation mechanism of "objective" functions, which integrate the Monte Carlo simulations to calculate the robustness of objective function and different constraints. Our approach has been validated by two applications implemented with Matlab™ for the minimization of cost and machining time, which has allowed obtaining simultaneously efficient and robust results and offering the possibility to choose beforehand a compromise between efficiency and robustness of solutions.

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Section: Application To the Turning Operation Casementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Efficient genetic algorithm for multi-objective robust optimization of machining parameters with taking into account uncertainties

Sahali

Belaidi²,

Serra³

2014

Int J Adv Manuf Technol

Self Cite

View full text Add to dashboard Cite

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“…The carbon fibers are responsible for carrying load, while the matrix serves to distribute, hold, and protect the fibers as well as to transmit the load [1][2][3]. This unique material structure contributes to the enhanced mechanical and structural properties and made CFRP an ideal substitute for metals.…”

Section: Introductionmentioning

confidence: 99%

Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP

Qin

et al. 2015

Int J Adv Manuf Technol

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Features of chip formation can inform the mechanism of a machining process. In this paper, a series of orthogonal cutting experiments were carried out on unidirectional carbon fiber reinforced polymer (UD-CFRP) under cutting speed of 0.5m/min. The specially designed orthogonal cutting tools and high-speed camera were used in this paper. Two main factors are found to influence the chip morphology, namely the depth of cut (DOC) and the fiber orientation (angle θ ), and the latter of which plays a more dominant role. Based on the investigation of chip formation, a new approach is proposed for predicting fracture toughness of the newly machined surface and the total energy consumption during CFRP orthogonal cutting is introduced as a function of the surface energy of machined surface, the energy consumed to overcome friction , and the energy for chip fracture. The results show that the proportion of energy spent on tool-chip friction is the greatest, and the proportions of energy spent on creating new surface decrease with the increasing of fiber angle.

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“…Gao et al [8] established a 3D finite element model for cutting unidirectional CFRP, and the simulation results showed that fiber orientation angle, cutting depth and cutting speed are the main influential factors of milling force and surface roughness. Chibane et al [9] conducted an experimental study on milling CFRP with a PCD cutter, and established the milling parameter optimization model for machining surface quality. Haddad et al [10,11] carried out a test in which milling of CFRP was performed with a coated carbide tool, and investigated the influential mechanism of cutting parameters on cutting force, cutting temperature and machining surface quality.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Milling CFRP with Staggered PCD Cutter

et al. 2017

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Carbon fiber reinforced plastics (CFRP) have good physical properties, such as high specific strength and high specific modulus. However, cutting delamination, tearing and burr, etc. often occur in the machining process of CFRP, which results in the uncontrollability of machining surface quality and serious tool wear. In this paper, milling of CFRP with a staggered cutter was carried out, the cutting-edge radius was investigated in order to characterize the tool wear; the effect of the cutting-edge wear radius on the milling force and surface quality was found, and the formation mechanisms of the 3D surface topography and surface defects were analyzed under the wear state. Experimental results showed that the wear of the staggered PCD cutter was mainly concentrated in the cutting-edge area. With the increase in milling length, the radius of cutting edge gradually became largeer under the action of abrasive wear mechanism, and the flank wear was not obvious. With the intension of tool wear, milling force gradually increased and the machining surface quality of the CFRP deteriorated distinctly, i.e., defects such as bare fiber fracture, groove and hole appeared, and burrs were gradually generated on the workpiece surface. Finally, through a comparative analysis of cutting performance, it was found that the staggered PCD cutter possessed better performance for wear resistance and burr suppression than the straight-teeth cutter. This finding can provide theoretical and technical support for improving the machining quality of carbon fiber composite materials.

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Optimal milling conditions for carbon/epoxy composite material using damage and vibration analysis

Cited by 26 publications

References 22 publications

Efficient genetic algorithm for multi-objective robust optimization of machining parameters with taking into account uncertainties

Efficient genetic algorithm for multi-objective robust optimization of machining parameters with taking into account uncertainties

Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP

Experimental Study on Milling CFRP with Staggered PCD Cutter

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