Abstract:The aim of this paper is to study the influence of the process parameters (cutting speed and feed) of the conventional trimming on cutting forces, machining temperatures, tool wear and machining quality of Carbon Fibers Reinforced Plastics (CFRP) using PCD tool. The machining quality was characterized using three different techniques such as Scanning Electron Microscopy (SEM), 3D optical topography and X-ray tomography. The originality of this work is based mainly on the multi-scale characterization of the mac… Show more
“…This is due to the fact that an increase in cutting speed and a decrease in feed speed generate minimum theoretical chip thickness which makes ease of machining. Similar phenomena were also observed in the studies of Sheikh-Ahmad et al 13 and Janardhan et al 25 Recently, Nguyen-Dinh et al 26 have revealed reverse results in which the combination of high cutting speed (250 m/min) and low feed speed (500 mm/min) generates severe damage in the machined surface. The difference of results between studies was explained by the authors.…”
Section: Introductionsupporting
confidence: 79%
“…The detailed descriptions of previous measurements can be found in Nguyen-Dinh et al. 26 Figure 4.Confocal microscope for 3D topography measurement.Figure 5.X-ray tomography for specimens analyzing.…”
Section: Methodsmentioning
confidence: 99%
“…25 Recently, Nguyen-Dinh et al. 26 have revealed reverse results in which the combination of high cutting speed (250 m/min) and low feed speed (500 mm/min) generates severe damage in the machined surface. The difference of results between studies was explained by the authors.…”
Machining of composite materials is a challenging task due to the heterogeneity and anisotropy of composite structures. The induced defects reduce integrity of the machined surface as well as the loading capacity of the composite structure in service. Therefore, it is necessary to quantify the damage induced during trimming and correlate the quality of the machined surface to mechanical properties. The correlation of the surface roughness criteria, widely used in literature, to the mechanical behavior raise several contradictions. For this reason, new parameters for the characterization of the machined surface are proposed and correlated to the mechanical behavior under compressive loading. In this context, carbon fiber-reinforced plastic laminates are conventionally trimmed, and the machining damage is characterized using scanning electron microscope observations, X-ray tomography, and 3D optical topography. The results reveal that crater volume and maximum depth of damage quantify the machining damage more realistic compared to the classical surface roughness criteria.
“…This is due to the fact that an increase in cutting speed and a decrease in feed speed generate minimum theoretical chip thickness which makes ease of machining. Similar phenomena were also observed in the studies of Sheikh-Ahmad et al 13 and Janardhan et al 25 Recently, Nguyen-Dinh et al 26 have revealed reverse results in which the combination of high cutting speed (250 m/min) and low feed speed (500 mm/min) generates severe damage in the machined surface. The difference of results between studies was explained by the authors.…”
Section: Introductionsupporting
confidence: 79%
“…The detailed descriptions of previous measurements can be found in Nguyen-Dinh et al. 26 Figure 4.Confocal microscope for 3D topography measurement.Figure 5.X-ray tomography for specimens analyzing.…”
Section: Methodsmentioning
confidence: 99%
“…25 Recently, Nguyen-Dinh et al. 26 have revealed reverse results in which the combination of high cutting speed (250 m/min) and low feed speed (500 mm/min) generates severe damage in the machined surface. The difference of results between studies was explained by the authors.…”
Machining of composite materials is a challenging task due to the heterogeneity and anisotropy of composite structures. The induced defects reduce integrity of the machined surface as well as the loading capacity of the composite structure in service. Therefore, it is necessary to quantify the damage induced during trimming and correlate the quality of the machined surface to mechanical properties. The correlation of the surface roughness criteria, widely used in literature, to the mechanical behavior raise several contradictions. For this reason, new parameters for the characterization of the machined surface are proposed and correlated to the mechanical behavior under compressive loading. In this context, carbon fiber-reinforced plastic laminates are conventionally trimmed, and the machining damage is characterized using scanning electron microscope observations, X-ray tomography, and 3D optical topography. The results reveal that crater volume and maximum depth of damage quantify the machining damage more realistic compared to the classical surface roughness criteria.
“…It is reasoned that reducing feed and increasing cutting speed has likely shown an improvement in surface quality because of the reduction in un-cut chip thickness, as verified by other researchers. 5…”
“…Previous research has shown that induced surface roughness in a milling and edge trimming operation is significantly affected by ply orientation and tool cutting edge radius (CER). [1][2][3][4][5] Cutting parameters and uncut chip thickness have additionally been shown to have a critical effect on machining induced surface quality and pitting magnitude. [6][7][8] Chen et al 9 have compiled a thorough analysis of the different types of cutting mechanism for the 0°, 45°, 90°and 135°fibre orientations, using micro textured tools in a composite milling process, and shown how fibre orientation will influence the machined surface quality.…”
Many carbon fibre reinforced polymer composite parts need to be edged trimmed before use to ensure both geometry and mechanical performance of the part edge matches the design intent. Measurement and control of machining induced surface damage of composite material is key to ensuring the part retains its strength and fatigue properties. Typically, the overall surface roughness of the machined face is taken to be an indicator of the amount of damage to the surface, and it is important that the measurement and prediction of surface roughness is completed reliably. It is known that the surface damage is heavily dependent on the fibre orientation of the composite and cutting tool edge condition. This research has developed a new ply-by-ply surface roughness measurement methods using optical focus variation surface analysis and image segmentation for calculating areal surface roughness parameters of a machined carbon fibre composite laminate. Machining experiments have been completed using a polycrystalline diamond edge trimming tool at increasing levels of cutting edge radius. Optical surface measurement and µ-CT scanning have been used to assess machining induced surface and sub-surface defects on individual fibre orientations. Statistical analysis has been used to assess the significance of machining parameters on Sa (arithmetic mean height of area) and Sv (areal magnitude of maximum valley depth) areal roughness parameters, on both overall roughness and ply-by-ply fibre orientations. Empirical models have been developed to predict surface roughness parameters using statistical methods. It has been shown that cutting edge degradation, fibre orientation and feed rate will significantly affect the cutting mechanism, machining induced surface defects and surface roughness parameters.
The primary factors affecting the geometric accuracy of abrasive water jet (AWJ) machining of ultra‐thick carbon fiber‐reinforced polymer (CFRP) laminates are the cutting front drag and kerf width deviation caused by energy dissipation. Firstly, this study comprehensively analyzes the influence of the coupling relationship between cutting front drag and kerf width deviation on the geometric accuracy of hole machining. Secondly, a gradient distribution theory for jet traverse speed with cutting depth is proposed for taper hole machining characteristics. Finally, a general geometric error model applicable to both straight and taper hole machining of ultra‐thick CFRP laminates using AWJ is established, along with a geometric error compensation method. A series of experiments validate the accuracy of the proposed geometric error model and compensation method. The novelty of this research lies in unifying the geometric error models for straight and taper hole machining of ultra‐thick CFRP laminates by considering the gradient distribution of jet traverse speed. The proposed error compensation method reduces the high degree of freedom required for machine tools. This study provides a general geometric error model and compensation strategy for AWJ hole machining of ultra‐thick CFRP laminates, which has significant engineering value for achieving 3D controllable AWJ machining of complex ultra‐thick CFRP components.Highlights
The high geometric precision taper holes machining technique is a necessary prerequisite for achieving precise machining of complex trajectories in ultra‐thick CFRP with abrasive water jet.
The influence of the coupling relationship between cutting front drag and kerf taper on the geometric accuracy of hole processing is comprehensively analyzed.
A model considering the gradient distribution of traverse speed during taper holes machining was established, and a geometric error model considering this gradient distribution of traverse speed was developed.
A taper holes machining geometric error compensation method with high engineering applicability was proposed.
Geometric error prediction experiments and error compensation experiments were conducted, and the results proved the accuracy of the geometric error model and error compensation method.
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