Skip to main content
SpringerLink
Log in

Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The application of carbon fiber reinforced thermoplastic matrix composites (CFRTP) is constantly increasing in various industrial sectors due to their mechanical properties and advantages compared to thermoset matrix composite. Nevertheless, CFRTP machining generates a current problem due to the anisotropy of these materials, the difficulty of impregnation of the reinforcement in the matrix, and its low melting temperature. For this reason, the study of conventional operations such as milling to achieve geometries with a good surface quality and reduced cosmetic defects is a line of research of great interest. In this article, a comparison of five cutting tools with different geometries has been made in CFRTP milling. The surface quality and the formation of visual defects such as fiber pull-out have been evaluated for each tool and combination of cutting parameters. In this sense, 16.42 μm in terms of Rz is the minimum average value for the complete experiment obtained for a conventional tool (tool A). However, surface qualities in terms of Rz close to 20 μm and minimum cosmetic defects have been obtained with a hybrid tool (tool C) with −10° helix angle and 8 teeth with a combination of cutting parameters of 0.07 mm/tooth and 3000 rpm, being the most complete tool of the experiment.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

Data availability

All the data have been presented in the manuscript.

Abbreviations

Rz:

average of the absolute values of the five highest peaks and the five lowest valleys

TPU:

thermoplastic polyurethane

C/TPU:

carbon/thermoplastic polyurethane

AWJM:

abrasive water jet machining

CFRP:

carbon fiber reinforced plastics with thermoset matrix

CFRTP:

carbon fiber reinforced thermoplastics

z:

number of teeth

Fz:

feed rate per tooth

S:

spindle speed

References

  1. Ahmad F, Manral A, Bajpai PK (2019) Machining of thermoplastic composites. In: Processing of Green Composites. Springer, Singapore, pp 107–123

    Chapter  Google Scholar 

  2. Arhant M, Davies P (2019) Thermoplastic matrix composites for marine applications. Elsevier Ltd., Amsterdam

    Book  Google Scholar 

  3. Bañon F, Sambruno A, Fernandez-Vidal S, Fernandez-Vidal SR (2019) One-shot drilling analysis of stack CFRP/UNS A92024 bonding by adhesive. Materials (Basel) 12:1–18. https://doi.org/10.3390/ma12010160

    Article  Google Scholar 

  4. Bañon F, Sambruno A, Batista M, Simonet B, Salguero J (2020) Surface quality and free energy evaluation of s275 steel by shot blasting, abrasive water jet texturing and laser surface texturing. Metals (Basel) 10. https://doi.org/10.3390/met10020290

  5. Chen Y, Guo X, Zhang K, Guo D, Zhou C, Gai L (2019) Study on the surface quality of CFRP machined by micro-textured milling tools. J Manuf Process 37:114–123. https://doi.org/10.1016/j.jmapro.2018.11.021

    Article  Google Scholar 

  6. Dhanawade A, Kumar S (2017) Experimental study of delamination and kerf geometry of carbon epoxy composite machined by abrasive water jet. J Compos Mater 51:3373–3390. https://doi.org/10.1177/0021998316688950

    Article  Google Scholar 

  7. El-Hofy M, Helmy MO, Escobar-Palafox G et al (2018) Abrasive water jet machining of multidirectional CFRP laminates. Procedia CIRP 68:535–540. https://doi.org/10.1016/j.procir.2017.12.109

    Article  Google Scholar 

  8. Fu R, Jia Z, Wang F, Jin Y, Sun D, Yang L, Cheng D (2018) Drill-exit temperature characteristics in drilling of UD and MD CFRP composites based on infrared thermography. Int J Mach Tools Manuf 135:24–37. https://doi.org/10.1016/j.ijmachtools.2018.08.002

    Article  Google Scholar 

  9. Geier N, Pereszlai C (2020) Analysis of characteristics of surface roughness of Machined CFRP composites. Period Polytech Mech Eng 64:67–80. https://doi.org/10.3311/PPme.14436

    Article  Google Scholar 

  10. Goto K, Imai K, Arai M, Ishikawa T (2019) Shear and tensile joint strengths of carbon fiber-reinforced thermoplastics using ultrasonic welding. Compos Part A Appl Sci Manuf 116:126–137. https://doi.org/10.1016/j.compositesa.2018.10.032

    Article  Google Scholar 

  11. Haddad M, Zitoune R, Bougherara H, Eyma F, Castanié B (2014) Study of trimming damages of CFRP structures in function of the machining processes and their impact on the mechanical behavior. Compos Part B 57:136–143. https://doi.org/10.1016/j.compositesb.2013.09.051

    Article  Google Scholar 

  12. Haddad M, Zitoune R, Eyma F, Castanie B (2014) Study of the surface defects and dust generated during trimming of CFRP: influence of tool geometry, machining parameters and cutting speed range. Compos Part A Appl Sci Manuf 66:142–154. https://doi.org/10.1016/j.compositesa.2014.07.005

    Article  Google Scholar 

  13. Hintze W, Cordes M, Koerkel G (2015) Influence of weave structure on delamination when milling CFRP. J Mater Process Technol 216:199–205. https://doi.org/10.1016/j.jmatprotec.2014.09.004

    Article  Google Scholar 

  14. Ishikawa T, Amaoka K, Masubuchi Y, Yamamoto T, Yamanaka A, Arai M, Takahashi J (2018) Overview of automotive structural composites technology developments in Japan. Compos Sci Technol 155:221–246. https://doi.org/10.1016/j.compscitech.2017.09.015

    Article  Google Scholar 

  15. Karataş MA, Gökkaya H (2018) A review on machinability of carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) composite materials. Def Technol 14:318–326. https://doi.org/10.1016/j.dt.2018.02.001

    Article  Google Scholar 

  16. Kerrigan K, O’Donnell GE (2016) On the relationship between cutting temperature and workpiece polymer degradation during CFRP edge trimming. Procedia CIRP 55:170–175. https://doi.org/10.1016/j.procir.2016.08.041

    Article  Google Scholar 

  17. Khairusshima MKN, Aqella AKN, Sharifah ISS (2017) Optimization of milling carbon fibre reinforced plastic using RSM. Procedia Eng 184:518–528. https://doi.org/10.1016/j.proeng.2017.04.122

    Article  Google Scholar 

  18. Khanna N, Pusavec F, Agrawal C, Krolczyk GM (2020) Measurement and evaluation of hole attributes for drilling CFRP composites using an indigenously developed cryogenic machining facility. Meas J Int Meas Confed 154:107504. https://doi.org/10.1016/j.measurement.2020.107504

    Article  Google Scholar 

  19. Masek P, Zeman P, Kolar P (2013) Development of a cutting tool for composites with thermoplastic matrix. Mod Mach Sci J 2013:423–427. https://doi.org/10.17973/MMSJ.2013

    Article  Google Scholar 

  20. Masek P, Zeman P, Kolar P, Holesovsky F (2019) Edge trimming of C/PPS plates. Int J Adv Manuf Technol 101:157–170. https://doi.org/10.1007/s00170-018-2857-1

    Article  Google Scholar 

  21. Nguyen D, Abdullah MS Bin, Khawarizmi R, et al (2020) The effect of fiber orientation on tool wear in edge-trimming of carbon fiber reinforced plastics (CFRP) laminates. Wear 450–451:203213. https://doi.org/10.1016/j.wear.2020.203213

  22. Nor Khairusshima MK, Muhammad Hafiz Zakwan B, Suhaily M, Sharifah ISS, Shaffiar NM, Rashid MAN (2018) The optimization study on the tool wear of carbide cutting tool during milling Carbon Fibre Reinforced (CFRP) using Response Surface Methodology (RSM). IOP Conf Ser Mater Sci Eng 290:012068. https://doi.org/10.1088/1757-899X/290/1/012068

    Article  Google Scholar 

  23. Ozkan D, Gok MS, Oge M, Karaoglanli AC (2019) Milling behavior analysis of Carbon Fiber-Reinforced Polymer (CFRP) composites. Mater Today Proc 11:526–533. https://doi.org/10.1016/j.matpr.2019.01.024

    Article  Google Scholar 

  24. Pahuja R, Ramulu M, Hashish M (2019) Surface quality and kerf width prediction in abrasive water jet machining of metal-composite stacks. Compos Part B Eng 175:107134. https://doi.org/10.1016/j.compositesb.2019.107134

    Article  Google Scholar 

  25. Pereira RBD, Lauro CH, Brandão LC, Ferreira JR, Davim JP (2019) Tool wear in dry helical milling for hole-making in AISI H13 hardened steel. Int J Adv Manuf Technol 101:2425–2439. https://doi.org/10.1007/s00170-018-3129-9

    Article  Google Scholar 

  26. Shengchao H, Yan C, Jiuhua X, Jingwen Z (2014) Experimental study of tool wear in milling multidirectional CFRP laminates. Mater Sci Forum 770:276–280. https://doi.org/10.4028/www.scientific.net/MSF.770.276

    Article  Google Scholar 

  27. Sui J, Wang C (2019) Machinability study of unidirectional CFRP laminates by slot milling. Int J Adv Manuf Technol 100:189–197. https://doi.org/10.1007/s00170-018-2730-2

    Article  Google Scholar 

  28. Turki Y, Habak M, Velasco R, Vantomme P (2017) Highlighting cutting mechanisms encountered in carbon/epoxy composite drilling using orthogonal cutting. Int J Adv Manuf Technol 92:685–697. https://doi.org/10.1007/s00170-017-0153-0

    Article  Google Scholar 

  29. Voss R, Seeholzer L, Kuster F, Wegener K (2017) Influence of fibre orientation, tool geometry and process parameters on surface quality in milling of CFRP. CIRP J Manuf Sci Technol 18:75–91. https://doi.org/10.1016/j.cirpj.2016.10.002

    Article  Google Scholar 

  30. Wang GD, Melly SK, Li N, Peng T, Li Y (2018) Research on milling strategies to reduce delamination damage during machining of holes in CFRP/Ti stack. Compos Struct 200:679–688. https://doi.org/10.1016/j.compstruct.2018.06.011

    Article  Google Scholar 

  31. Wang G, Stephen Kirwa M, Li N (2018) Experimental studies on a two-step technique to reduce delamination damage during milling of large diameter holes in CFRP/Al stack. Compos Struct 188:330–339. https://doi.org/10.1016/j.compstruct.2018.01.039

    Article  Google Scholar 

  32. Wang B, Chang K, Wang M, Zhang F, Zhang YF, Zheng YH (2018) Experimental studies on helical milling process to improve hole quality for the superalloy (MSRR7197). Int J Adv Manuf Technol 99:1449–1458. https://doi.org/10.1007/s00170-018-2588-3

    Article  Google Scholar 

  33. Xu J, Li C, Chen M, el Mansori M, Ren F (2019) An investigation of drilling high-strength CFRP composites using specialized drills. Int J Adv Manuf Technol 103:3425–3442. https://doi.org/10.1007/s00170-019-03753-8

    Article  Google Scholar 

  34. Xu J, Huang X, Chen M, Paulo Davim J (2020) Drilling characteristics of carbon/epoxy and carbon/polyimide composites. Mater Manuf Process 00:1–9. https://doi.org/10.1080/10426914.2020.1784935

    Article  Google Scholar 

  35. Xu J, Lin T, Chen M, Davim JP (2020) Machining responses of high-strength carbon/epoxy composites using diamond-coated brad spur drills. Mater Manuf Process 36:1–8. https://doi.org/10.1080/10426914.2020.1854475

    Article  Google Scholar 

  36. Xu J, Huang X, Davim JP, Ji M, Chen M (2020) On the machining behavior of carbon fiber reinforced polyimide and PEEK thermoplastic composites. Polym Compos 41:3649–3663. https://doi.org/10.1002/pc.25663

    Article  Google Scholar 

  37. Yao S, Jin F, Rhee KY et al (2018) Recent advances in carbon-fiber-reinforced thermoplastic composites: a review. Compos Part B 142:241–250. https://doi.org/10.1016/j.compositesb.2017.12.007

    Article  Google Scholar 

Download references

Funding

This work has been developed under support of a pre-doctoral industrial fellow financed by NANOTURES SL, mechanical engineering and industrial design department, and Vice-rectorate of Transference and Technological Innovation of the University of Cadiz.

Author information

Authors and Affiliations

  1. Faculty of Engineering, Mechanical Engineering and Industrial Design Department, University of Cadiz, Av. Universidad de Cadiz 10, E-11519, Puerto Real, Cadiz, Spain

    Alejandro Sambruno, Fermin Bañon, Jorge Salguero & Moises Batista

  2. Nanotures SL, C. Inteligencia 19, Tecnoparque Agroalimentario, E-11591, Jerez de la Frontera, Cadiz, Spain

    Bartolome Simonet

Authors
  1. Alejandro Sambruno
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Fermin Bañon
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jorge Salguero
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Bartolome Simonet
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Moises Batista
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

A.S. and F.B. developed machining tests. M.B. and J.S. developed data treatment. F.B., A.S., M.B., B.S., and J.S. analyzed the influence of the parameters involved. F.B. and A.S. collaborated in preparing figures and tables and F.B., A.S., M.B., B.S., and J.S. wrote the paper.

Corresponding author

Correspondence to Alejandro Sambruno.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sambruno, A., Bañon, F., Salguero, J. et al. Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions. Int J Adv Manuf Technol 114, 2515–2526 (2021). https://doi.org/10.1007/s00170-021-07050-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07050-1

Keywords

Search

Navigation