Abstract
In the aviation industry, increasing research and applications of carbon fibres have led to a higher demand of carbon fibre reinforced polymer (CFRP) material. The moulding process of CFRP material is not precise enough to be directly moulded into its end form and an additional machining process is required. The machining of CFRP materials can result into generation of defects such as fibre overhang, cracking and delamination. Normally, the visual quality checks are carried out after machining is completed and hence, the damage at the end of the process is significantly more which can result into rework or rejection of the product. To solve this problem, an online quality monitoring system was developed in which the defects were measured, processed and identified online during the milling process. In order to achieve this, a line sensor was mounted behind the tool, which followed the tool and captured the data of the edge while milling. In the end, defects such as fibre overhang and delamination were detected simultaneously during the milling process.
Similar content being viewed by others
References
VDI ZRE Publikationen: Kohlenstofffaserverstärkte Kunststoffe im Fahrzeugbau—Ressourceneffizienz und Technologien (2013)
Roland Berger Strategy Consultants: Serienproduktion von hochfesten Faserverbundbauteilen (2012)
Davim, J., Rubio, J., Abrao, A.: A novel approach based on digital image analysis to evaluate the delamination factor after drilling composite laminates. Compos. Sci. Technol. 67, 1939–1945 (2007)
Hintze, W., Hartmann, D., Schütte, C.: Occurrence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs)—an experimental study. Compos. Sci. Technol. 71, 1719–1726 (2011)
Karpat, Y., Bahtiyar, O., Değer, B.: Milling force modelling of multidirectional carbon fiber reinforced polymer laminates. Proced. CIRP 1, 460–465 (2012)
Benati, F., Butler, C., Gatti, S., Sacerdotti, F., Yang, Q.: A robot-based burr measurement system for the automotive industry. Instrumentation and Measurement Technology Conference, 1999. IMTC/99. In: Proceedings of the 16th IEEE. Institute of Electrical and Electronics Engineers; Piscataway N.J.; IEEE Service Center, New York N.Y. (1999)
Hoang, H.P., To, H.M., Ko, S.L.: Measurement technology using Z axis adaptation for burrs formed on curved surfaces. J. Mech. Sci. Technol. 29, 3459–3465 (2015)
Lee, W.K., Ratnam, M.M., Ahmad, Z.A.: In-process detection of chipping in ceramic cutting tools during turning of difficult-to-cut material using vision-based approach. Int. J. Adv. Manuf. Technol. 85, 1275–1290 (2016)
Fofi, D., Sliwa, T., Voisin, Y.: A comparative survey on invisible structured light, p. 90 (2004)
Burrus, C.S., Gopinath, R.A., Guo, H.: Introduction to wavelets and wavelet transforms. A primer. Prentice Hall, Upper Saddle River (1998)
Chun-Lin, L.: A tutorial of the wavelet transform. In: NTUEE, Taiwan (2010)
Stark, H.-G.: Wavelets and signal processing. An application-based introduction. Springer, Berlin (2005)
Cooley, J.W., Tukey, J.W.: An algorithm for the machine calculation of complex fourier series. Math. Comput. 19, 297 (1965)
Ko, S.L., Park, S.W.: Development of an effective measurement system for burr geometry. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 220, 507–512 (2006)
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Electronic supplementary material
Below is the link to the electronic supplementary material.
Rights and permissions
About this article
Cite this article
Rawal, P., Brillinger, C., Böhlmann, C. et al. Sensor based online quality monitoring system for detection of milling defects on CFRP structures. CEAS Aeronaut J 11, 565–574 (2020). https://doi.org/10.1007/s13272-019-00436-8
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13272-019-00436-8