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Rake angle effects on ultrasonic-assisted edge trimming of multidirectional CFRP laminates

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Abstract

Machining of CFRP composites is usually described as a challenging process from tool life and surface quality perspectives. To achieve a flawless machined surface at reasonable cutting tool life/cost, an optimum combination of cutting tool material and geometry is the key. The cutting tool angles are of importance as these dictate the cutting mechanism as well as the cutting edge robustness and the introduction of vibration to the machining process opens up new horizons of improvement and stirs further research questions. This article investigates the effect of tools with different geometry possessing different rake angles when used in ultrasonic-assisted edge trimming operation dealing with multidirectional CFRP laminates. A full-factorial experimental design was adopted to analyze the effect of process parameters typically cutting speed, feed rate, rake angle, amplitude, and their interactions. Machining performance indicators were captured which were the cutting forces, tool wear, chip temperature, and surface roughness. The results showed that UAM mode contributed to an increase in the cutting forces, tool wear, and chip temperature compared to the conventional mode. On the other hand, UAM mode improved the quality of the machined surface. Additionally, the ultrasonic mode enhanced the material removal mechanism using a tool with a negative rake angle.

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Acknowledgements

The authors would like to thank the Mission Department of the Ministry of Higher Education in Egypt (MoHE) and Tokyo University of Agriculture and Technology for facilitating the access to Sasahara Lab, and the OSG Corporation for supplying the tools and to thank Airbus for the material used in this research.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Benha Faculty of Engineering, Benha University, Benha, 13518, Egypt

    Mohamed O. Helmy

  2. Industrial and Manufacturing Engineering Department, School of Innovative Design Engineering, Egypt-Japan University of Science and Technology (E-JUST), Alexandria, 21934, Egypt

    Hassan El-Hofy & M. H. El-Hofy

  3. Faculty of Engineering, Alexandria University, Alexandria, 21544, Egypt

    Hassan El-Hofy

  4. Department of Mechanical Systems Engineering, Tokyo University of Agriculture and Technology, 2-24-16 Naka-cho, Koganei, Tokyo, 184-8588, Japan

    Hiroyuki Sasahara

  5. Advanced Manufacturing Research Centre with Boeing, The University of Sheffield, Advanced Manufacturing Park, Wallis way, Rotherham, S60 5TZ, UK

    M. H. El-Hofy

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  1. Mohamed O. Helmy
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  2. Hassan El-Hofy
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  3. Hiroyuki Sasahara
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  4. M. H. El-Hofy
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Correspondence to Mohamed O. Helmy.

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Helmy, M.O., El-Hofy, H., Sasahara, H. et al. Rake angle effects on ultrasonic-assisted edge trimming of multidirectional CFRP laminates. Int J Adv Manuf Technol 115, 3467–3484 (2021). https://doi.org/10.1007/s00170-021-07383-x

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  • DOI: https://doi.org/10.1007/s00170-021-07383-x

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