Rotary ultrasonic machining of carbon fiber reinforced plastic composites: An experimental study on cutting temperature

Abstract

Carbon fiber reinforced plastic composites are used in many applications due to their superior properties. Drilling is the most frequently used machining process due to the need for assembly of carbon fiber reinforced plastic parts in mechanical structures. Rotary ultrasonic machining has been successfully used in drilling carbon fiber reinforced plastic composites. Reported investigations on rotary ultrasonic machining of carbon fiber reinforced plastic cover several output variables (including cutting force, torque, surface roughness, material removal rate, fiber delamination, tool wear, and power consumption). However, there are no reported studies on cutting temperature in rotary ultrasonic machining of carbon fiber reinforced plastic. This paper presents an experimental study on cutting temperature in rotary ultrasonic machining of carbon fiber reinforced plastic using two measurement methods (thermocouple and fiber optic sensor). Comparisons between these two methods are made and relations between input variables (ultrasonic power, tool rotation speed, and feedrate) and cutting temperature are experimentally determined.

Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

“…Another typical application of this tool (in the shape of a hollow cylinder, named diamond core drill) consists in grinding holes on CFRP components in rotary ultrasonic elliptical machining (RUEM) and rotary ultrasonic machining (RUM). Excellent chip removal conditions and the high machined surface quality were achieved in both of the processes [15][16][17][18]. Thus, ultrasonic vibration assisted milling with diamond grinding tool may provide a satisfactory approach to overcome the associated problems in conventional grinding of CFRP.…”

Experimental investigations on core drilling by ultrasonic-vibration-assisted grinding for hard-to-machine materials - a review

“…Seven brittle materials (Al 2 O 3 , ZrO 2 / Al 2 O 3 , dental ceramics, SiC, poly-crystalline, CMC, and silicon), two ductile materials (Ti and stainless steel) and two carbon fibre composites (C/C, CFRP) were studied. Seven of the 13 input variables were studied for ductile materials, six of them for brittle materials and only two of them for carbon fibre composites (Cong et al, 2011(Cong et al, , 2013a(Cong et al, , 2012a(Cong et al, , 2012b(Cong et al, , 2012c2012d;Ma, 2013). There is a phenomena that cutting force in UVAG was lower than that in traditional diamond grinding.…”

“…In addition, torque decreased with the increase of ultrasonic vibration amplitude and tool rotational speed and the decrease of feedrate in UVAG of carbon fibre composites. Also, using variable feedrate method (explained in Section 9) or cutting fluid, torque could be lower than using a fixed feedrate method or cold air (Cong et al, 2011(Cong et al, , 2013a(Cong et al, , 2012c(Cong et al, , 2012d.…”

“…It is reported that UVAG has six to ten times higher MRR than traditional grinding , and it is about ten times faster than ultrasonic machining (USM) (Cleave, 1976). Tool pressure and torque in UVAG are low (Cleave, 1976;Cusumano et al, 1974;Cong et al, 2011Cong et al, , 2013aCong et al, , 2012cCong et al, , 2012d: lower pressure is especially helpful when drilling small holes, deep holes, or adjacent holes with thin dividing walls (Cleave, 1976). UVAG also has reduced edge chipping, breakout and damage (Cleave, 1976).…”

Modelling thermal effects in machining of carbon fiber reinforced polymer composites

“…In a recent work, 10 an experimental study on cutting temperature in rotary ultrasonic machining of carbon fiber reinforced plastic using two measurement methods was presented: a novel method based on fiber optic sensor and a well-known technique based on thermocouples. Both methods were compared, and the relations between input variables (ultrasonic power, tool rotation speed, and feed rate) and cutting temperature were experimentally determined.…”