Abstract
Because of the low thermal conductivity of Carbon Fibre Reinforced Polymers (CFRPs) during high speed-trimming, cutting forces and tool wear significantly increase the temperature at the contact zone, which is then completely transferred to the cutting tool and exceeds the permitted thermal stability limit of the cutting material. This then leads to a drastic reduction of the tool life, thermal damage, poor quality, and in some cases, rejection of machined parts. This paper presents the development of tool wear and cutting force prediction models in the trimming of CFRPs. A 3/8 in. diameter CVD diamond-coated carbide tool with six straight flutes was used to trim 24-ply carbon fibre laminates. The results obtained using a scanning electron microscope (SEM) showed increasing defect rates with increased tool wear. Two models were adjusted to predict tool wear and cutting force for different values of cutting speed, feed and cutting length. One of them is a multiplicative statistical model, and the other, an exponential model. Outcomes from the two models were analysed and compared. The ANOVA approach was also used to test the overall significance of the models by applying F-tests. The results obtained show that the exponential model is better capable of accurately predicting the cutting force and tool wear under the conditions studied. To enhance the prediction accuracy of the tool wear model, the cutting force was added as a variable in the tool wear model. Results show that the enhanced multiplicative model provided higher predictive capabilities than the exponential model.
Similar content being viewed by others
References
Davim JP (2010) Machining composite materials. Wiley, London
Sheikh-Ahmad JY (2009) Machining of polymer composites. Springer, New York
Jenarthanan MP, Jeyapaul R (2013) Optimisation of machining parameters on milling of GFRP composites by desirability function analysis using Taguchi method. Int J Eng Sci Technol 5(4):23–36
Lacoste E, Szymanska K, Terekhina S, Fréour S, Jacquemin F, Salvia M (2013) A multi-scale analysis of local stresses development during the cure of a composite tooling material. Int J Mater Form 6:467–482
Teti R (2002) Machining of composite materials. CIRP Ann Manuf Technol 51:611–634
Chen X, Xie H, Chen H, Zhang F (2010) Optimization for CFRP pultrusion process based on genetic algorithm-neural network. Int J Mater Form 3(2):1391–1399
Everstine G, Rogers T (1971) A theory of chip formation of FRP composite materials. J Comput Mater Sci 5:94–106
Koplev A (1980) Cutting of CFRP with single edge tools. Proc 3rd Int Conf Compos Mater Paris 2:1597–1605
Koplev A, Lystrup A, Vorm T (1983) The cutting process, chips and cutting forces in machining CFRP. Composites 14:371–376
Takeyama H, Iijima N (1988) Machinability of glass fiber reinforced plastics and application of ultrasonic machining. Ann CIRP 37(1):93–96
Hocheng H, Puw H, Huang Y (1993) Preliminary study on milling of unidirectional carbon-fibre reinforced plastics. Compos Manuf 4(2):103–108
Hintze W, Hartmann D, Schutte C (2011) Occurrence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs): an experimental study. Compos Sci Technol 71(15):1719–1726
Kalla D, Sheikh-Ahmad J, Twomey J (2010) Prediction of cutting forces in helical end milling fiber reinforced polymers. Int J Mach Tools Manuf 50:882–891
Phadnis VA, Roy A, Silberschmidt VV (2012) Finite element analysis of drilling in carbon fiber reinforced polymer composites. J Phys Conf Ser 382:012014. doi:10.1088/1742-6596/382/1/012014
Rao GVG, Mahajan P, Bhatnagar N (2007) Machining of UD-GFRP composites chip formation mechanism. Compos Sci Technol 67(11–12):2271–2281
Arola D, Ramulu M (1997) Orthogonal cutting of fiber-reinforced composites: a finite element analysis. Int J Mech Sci 39(5):597–613
Mkaddem A, Demirci I, Mansori ME (2008) A micro–macro combined approach using FEM for modelling of machining of FRP composites: cutting forces analysis. Compos Sci Technol 68(15–16):3123–3127
Jahromi AS, Bahr B (2010) An analytical method for predicting cutting forces in orthogonal machining of unidirectional composites. Compos Sci Technol 70:2290–2297
Haiyan W, Xuda Q, Hao L et al (2012) Analysis of cutting forces in helical milling of carbon fiber-reinforced plastics. Proc Inst Mech Eng B J Eng Manuf. doi:10.1177/0954405412464328
Karpat Y, Polat N (2013) Mechanistic force modeling for milling of carbon fiber reinforced polymers with double helix tools. CIRP Ann Manuf Technol. doi:10.1016/j.cirp.2013.03.105
Zaghbani I, Chatelain J-F, Berube S et al (2012) Analysis and modelling of cutting forces during the trimming of unidirectional CFRP composite laminates. Int J Mach Mach Mater 12(4):337–357
Caprino G, De Iorio I, Nele L, Santo L (1996) Effect of tool wear on cutting forces in the orthogonal cutting of unidirectional glass fibre reinforced plastics. Compos Part A 27a:409–415
Palanikumar K, Davim JP (2009) Assessment of some factors influencing tool wear on the machining of glass fibre-reinforced plastics by coated cemented carbide tools. J Mater Process Technol 209:511–519
Chen WC (1997) Some experimental investigations in the drilling of carbon fiber- reinforced plastic (CFRP) composite laminates. Int J Mach Tools Manuf 37(8):1097–1108
Davim JP, Reis P (2003) Study of delamination in drilling carbon fiber reinforced plastics (CFRP) using design experiments. Compos Struct 59(4):481–487
Lin SC, Chen IK (1996) Drilling carbon fiber-reinforced composite material at high speed. Wear 194:156–162
Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tools Manuf 49:1185–1196
Iliescu D, Gehin D, Gutierrez ME, Girot F (2010) Modeling and tool wear in drilling of CFRP. Int J Mach Tools Manuf 50:204–213
Wang X, Wang C, Shi R et al (2012) Research on the effect of low temperature on the performance of drilling Carbon Fibre Reinforced Polymer and Ti Stack Materials. Mater Sci Forum 723:30–34
Khairusshima N, Hassan C, Jaharah A et al (2011) Tool wear and surface roughness on milling carbon fiber-reinforced plastic using chilled air. J Asian Sci Res 2(11):593–598
Rahman M, Ramakrishna S, Prakash JRS, Tan DCG (1999) Machinability study of carbon fiber reinforced composite. J Mater Process Technol 89(90):292–297
Shengchao H, Yana CH, Jiuhua X, Jingwen Z (2014) Experimental study of tool wear in milling multidirectional CFRP laminates. Mater Sci Forum 770:276–280
Berube S (2012) Évaluation de la performance d’outils de coupe dédiés au détourage de structures composites carbone/époxy. Master dissertation, École de technologie supérieure
ISO Standard 8688–2 (1989) International standard for tool life testing in end milling, part 2, 1st edn, 1989-05-01
Mason RL, Gunst RF, Hess J-L (2003) Statistical design and analysis of experiments, with applications to engineering and science. Wiley, Hoboken
Acknowledgments
This work was funded by the Natural Sciences and Engineering Research Council of Canada (NSERC) and the Consortium for Research and Innovation in Aerospace in Québec (CRIAQ) and its partners, MITACS, Bombardier Aerospace, Avior Integrated Products, Delastek and Av&R Vision & Robotics.
Author information
Authors and Affiliations
Corresponding author
Appendix
Appendix
Rights and permissions
About this article
Cite this article
Slamani, M., Chatelain, JF. & Hamedanianpour, H. Comparison of two models for predicting tool wear and cutting force components during high speed trimming of CFRP. Int J Mater Form 8, 305–316 (2015). https://doi.org/10.1007/s12289-014-1170-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12289-014-1170-2