Thermal aspects in machining CFRPs: effect of cutter type and cutting parameters

Sheikh-Ahmad, Jamal; Almaskari, Fahad; Hafeez, Farrukh

doi:10.1007/s00170-018-2881-1

Cited by 25 publications

(26 citation statements)

References 21 publications

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“…In this case, the frictional phenomenon is more pronounced and the local temperature of machining can reach the glass transition temperature (Tg) of the matrix which favors the adhesion of the microchips on the active surface of the tool as well as in the grooves. Similar phenomenon is observed in the work of Sheikh-Ahmad et al [25] and Haddad et al [4,19], when trimming is conducted with burr tool where the temperature of machining recorded in vicinity of the active surface of the tool (grooves) is superior to the T g of the matrix material in the CFRP. The same phenomenon of the dust adhesion to the cutting tool has been observed by Haddad et al [19] when using burr tool.…”

Section: Influence Of Grooves On the Cutting Edge On The Number Of Harmful Particlessupporting

confidence: 84%

New tool for reduction of harmful particulate dispersion and to improve machining quality when trimming carbon/epoxy composites

Nguyen-Dinh

Hejjaji

Zitoune

et al. 2020

Composites Part A: Applied Science and Manufacturing

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Conventional machining of carbon fiber reinforced plastic composites (CFRPs) generates minute chips that get suspended in air causing a hazard compromising operator safety. This study investigates the influence of cutting parameters (feed speed, cutting speed, radial depth of cut, tool geometry and tool wear) during trimming of CFRP on the form and quantity of harmful particles dispersed. Also, performance of two classical PCD tool geometries (two straight flutes, two helix flutes) have been compared with newly designed (in collaboration with ASAHI Company) four serrated straight flutes for the purpose of dust emission reduction. The quantification of the number of harmful particles was estimated using laser spectroscopic dust monitor. The results reveal that, trimming with a combination of higher feed speed and lower cutting speed can reduce the dispersion of harmful particles. Further, the four serrated straight flutes recorded the least number of harmful particles compared to the conventional tools.

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Section: Influence Of Grooves On the Cutting Edge On The Number Of Harmful Particlessupporting

confidence: 84%

New tool for reduction of harmful particulate dispersion and to improve machining quality when trimming carbon/epoxy composites

Nguyen-Dinh

Hejjaji

Zitoune

et al. 2020

Composites Part A: Applied Science and Manufacturing

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“…Other research has shown that cutting parameters and thermal effects generated by machining can affect optically measured surface roughness parameters. [16][17][18] Sheikh-Ahmad et al 19 showed that surface topography will be dependent upon local fibre orientation and machining parameters. Reducing chip effective thickness (which is a function of feed and cutting speed) produced an improved surface quality, which was shown using the R Z (10 point average) roughness parameter.…”

Section: Introductionmentioning

confidence: 99%

Towards intelligent CFRP composite machining: Surface analysis methods and statistical data analysis of machined fibre laminate surfaces

Duboust

Watson

Marshall

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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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.

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“…Currently known methods and techniques for measuring cutting temperature can be classified into calorimetric, thermocouples [ 10 , 12 , 13 , 14 , 17 , 37 , 38 , 39 ], and thermographic methods [ 7 , 10 , 11 , 12 , 13 , 15 , 22 , 23 , 31 , 37 ]. The most common methods of measuring cutting temperatures during machining CFRP/metal stacks are the thermographic and thermocouple methods.…”

Section: Introductionmentioning

confidence: 99%

“…In a comparative study of experimental and numerical modeling of CFRP milling with different type cutters using the thermographic method, it was measured that the temperature of the cutter raised to 250 °C regardless of the cutter type, cutting speed, and feed. Using the thermocouple embedded into the CFRP workpiece, it was found that only 16% of the heat energy moved in a workpiece, from 30% to 46% in the cutter, and the rest transferred into the chip and the air [ 13 , 37 ]. In the experimental study, it was determined that, for avoiding delamination damage, the drilling area temperature should be lower than the glass transition temperature but higher than the brittle deformation of the epoxy resin [ 38 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Study of Drilling Temperature, Geometrical Errors and Thermal Expansion of Drill on Hole Accuracy When Drilling CFRP/Ti Alloy Stacks

et al. 2020

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The drilling of holes in CFRP/Ti (Carbon Fiber-Reinforced Plastic/Titanium alloy) alloy stacks is one of the frequently used mechanical operations during the manufacturing of fastening assemblies in temporary civil aircraft. A combination of inhomogeneous behavior and poor machinability of CFRP/Ti alloy stacks in one short drilling brought challenges to the manufacturing community. The impact of the drilling temperature and time delay factor under various cutting conditions on hole accuracy when machining CFRP/Ti alloy stacks is poorly studied. In this paper, the drilling temperature, the phenomenon of thermal expansion of the drill tool, and hole accuracy are investigated. An experimental study was carried out using thermocouples, the coordinate measuring machine method, and finite element analysis. The results showed that the time delay factor varied from 5 (s) to 120 (s), influences the thermal-dependent properties of CFRP, and leads to an increase in hole roundness. Additionally, the thermal expansion of the drill significantly contributes to the deviation of the hole diameter in Ti alloy.

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Thermal aspects in machining CFRPs: effect of cutter type and cutting parameters

Cited by 25 publications

References 21 publications

New tool for reduction of harmful particulate dispersion and to improve machining quality when trimming carbon/epoxy composites

New tool for reduction of harmful particulate dispersion and to improve machining quality when trimming carbon/epoxy composites

Towards intelligent CFRP composite machining: Surface analysis methods and statistical data analysis of machined fibre laminate surfaces

Experimental Study of Drilling Temperature, Geometrical Errors and Thermal Expansion of Drill on Hole Accuracy When Drilling CFRP/Ti Alloy Stacks

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