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

Xu, Ziyang; Wang, Yongguo

doi:10.3390/ma15113862

Cited by 6 publications

(5 citation statements)

References 39 publications

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“…The process is carried out by a conventional milling machine (see Figure 4 -left) with a high rate of success. The milling of CFRPs is known to relate the cutting method and tools with the forces and the surface quality [ 40 , 41 , 42 ]. Different strategies and methods have been studied to improve the milling performance, typically in respect to the delamination issue [ 43 , 44 ].…”

Section: Resultsmentioning

confidence: 99%

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

2022

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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.

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Section: Resultsmentioning

confidence: 99%

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

2022

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“…And then, these changes in the edge geometry led to an increase in rake angle γ(t) and bandwidth of the flank wear VB for both the bottom edge and side edge. According to Equation (7), it generated more heat to induce the rising of cutting temperature. The rising cutting temperature in turn aggravated the wear of the tool, thus causing the cutting temperature to keep rising, forming a vicious circle.…”

Section: Cutting Temperaturementioning

confidence: 99%

“…This combination makes its density less than 1/4 of that of steel [4,5]. In terms of material performance, thanks to the extraordinary properties of carbon fiber, such as high strength, high modulus, heat resistance and corrosion resistance, CFRP composites can overcome challenges from high temperature, complex impact and radiation [6,7]. However, suffering from the non-homogenous and anisotropic properties of composites structure and high abrasion resistance of carbon fibers and high abrasiveness of carbon fibers, the machining of CFRP composites is much harder than that of traditional metal materials, which can easily induce tool wear [8,9].…”

Section: Introductionmentioning

confidence: 99%

Research on Tool Wear and Surface Integrity of CFRPs with Mild Milling Parameters

Qiu

Zhang

et al. 2023

Coatings

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Carbon fiber-reinforced polymer composites are widely used in aviation and aerospace applications due to their excellent mechanical properties. Numerous studies have focused on tool wear at extreme machining parameters (f ≥ 540 mm/min) to accelerate tool wear experiments. However, using mild machining parameters is also instructive for current process production. To investigate the effect of wear on the surface integrity of CFRPs under mild parameters, a tool wear experiment on CFRPs was carried out at a conventional feed rate (f = 60 mm/min). The results show a cutting temperature increase of 47%, a cutting force increase of 53% and a flank wear width increase of 282% for PCD tools (with mild milling parameters) from 0 to 100 m of cutting length. As the cutting temperature reaches the glass transition temperature, Tg, during the stable wear stage, severe burrs and a large number of cavities appeared on the groove, and the subsurface with granular wear on flank wear land due to the transform of the matrix. Furthermore, Ra and Rz exhibit good indicators of cutting length and subsurface damage.

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“…These properties include fiber orientation, fiber and matrix volume fraction, as well as the presence of voids and cracks. Since CFRP composites consist of a reinforced phase (carbon fiber) and a continuous phase (epoxy resin), the machining process for CFRP is more complex compared to that of homogeneous materials [ 6 , 7 ].…”

Section: Introductionmentioning

confidence: 99%

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

Knápek,

Dvořáčková,

Váňa

2023

Materials

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This study aimed to investigate the effect of the clearance angle of the milling tool on wear, cutting forces, machined edge roughness, and delamination during non-contiguous milling of carbon-fiber-reinforced plastic (CFRP) composite panels with a twill weave and 90° fiber orientation. To achieve the objective of the study, it was first necessary to design suitable tools (6 mm diameter sintered carbide shank milling cutters) with a variety of clearance angles (8.4°, 12.4°, and 16.4°) and all the machinery and measuring equipment for the research to be carried out. Furthermore, measurement and evaluation methods for cutting tool wear, cutting forces, machined edge roughness, and delamination were developed. Last but not least, the results obtained during the research were summarized and evaluated. From the experiments conducted in this study, it was found that the tool clearance angle has a significant effect on tool wear, roughness of the machined surface, and delamination of the carbon fiber composite board. The tool with a clearance angle of 8.4° wore faster than the tool with a clearance angle of 16.4°. The same trend was observed for cutting force, machined surface roughness, and delamination. In this context, it was also shown that the cutting force increased as the tool wear increased, which in turn increased surface roughness and delamination. These results are of practical significance, not only in terms of the quality of the machined surface but also in terms of time, cost, and energy savings when machining CFRP composite materials.

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

Cited by 6 publications

References 39 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

Research on Tool Wear and Surface Integrity of CFRPs with Mild Milling Parameters

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

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