Advertisement

Effects of cutting edge radius and fiber cutting angle on the cutting-induced surface damage in machining of unidirectional CFRP composite laminates

  • Fu-ji Wang
  • Jun-wei Yin
  • Jian-wei MaEmail author
  • Zhen-yuan Jia
  • Fan Yang
  • Bin Niu
ORIGINAL ARTICLE

Abstract

Carbon fiber reinforced polymer composite laminates are anisotropic, inhomogeneous, and mostly prepared in laminate form before undergoing the finishing operations. The edge trimming process is considered as one of the most common finishing operations in the industrial applications. However, the laminate surface is especially prone to damage in the chip formation process, and the most common damage mode is burrs. Burrs may increase cost and production time because of additional machining; they can also damage the surface integrity. Many studies have been done to address this problem, and techniques for reducing burr size in material removal process has been the focus of the research. Nonetheless, the combined effects of the cutting edge radius and the fiber cutting angle on the burr formation have seldom been conducted, which in turn restricts to find out the mechanism of burr formation. The purpose of the present paper is to study the particular mechanism that leads to burr formation in edge trimming of CFRP laminates and investigate the effects of fiber cutting angle and cutting edge radius on burr formation. The results indicate that the burrs are prone to form in the fiber cutting angle range of 0° < χ < 90° when a large cutting edge radius of the tool is used for both milling and drilling of CFRP composites.

Keywords

Composite CFRP Machining Damage Cutting edge radius Fiber cutting angle 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Lazar MB, Xirouchakis P (2011) Experimental analysis of drilling fiber reinforced composites. Int J Mach Tool Manu 51(12):937–946CrossRefGoogle Scholar
  2. 2.
    Ning FD, Cong WL, Pei ZJ, Treadwell C (2016) Rotary ultrasonic machining of CFRP: a comparison with grinding. Ultrasonics 66:125–132CrossRefGoogle Scholar
  3. 3.
    Ning FD, Cong WL (2015). Rotary ultrasonic machining of CFRP: design of experiment with a cutting force model. ASME 2015 International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers V001T02A040-V001T02A040Google Scholar
  4. 4.
    Soutis C (2005) Fibre reinforced composites in aircraft construction. Prog Aerosp Sci 41(2):143–151CrossRefGoogle Scholar
  5. 5.
    Uhlmann E, Sammler F, Richarz S, Heitmüller F, Bilz M (2014) Machining of carbon fibre reinforced plastics. Procedia CIRP 2014(24):19–24CrossRefGoogle Scholar
  6. 6.
    Wang H, Ning FD, Hu Y, Fernando P. K. S. C., Pei ZJ, Cong WL. (2016). Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: effects of tool variables. Advan Mech Eng 8(9):1687814016670284Google Scholar
  7. 7.
    Wang H, Sun J, Li J, Lu L, Li N (2016) Evaluation of cutting force and cutting temperature in milling carbon fiber-reinforced polymer composites. Int J Adv Manuf Technol 82(9–12):1517–1525CrossRefGoogle Scholar
  8. 8.
    Brinksmeier E, Fangmann S, Rentsch R (2011) Drilling of composites and resulting surface integrity. CIRP Ann-Manuf Techn 60(1):57–60CrossRefGoogle Scholar
  9. 9.
    Colligan K, Ramulu M (1992) The effect of edge trimming on composite surface plies. Manufacturing Review (USA) 5(4):274–283Google Scholar
  10. 10.
    Gaitonde VN, Karnik SR, Rubio JC, Correia AE, Abrao AM, Davim JP (2008) Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites. J Mater Process Tech 203(1):431–438CrossRefGoogle Scholar
  11. 11.
    Bhatnagar N, Ramakrishnan N, Naik NK, Komanduri R (1995) On the machining of fiber reinforced plastic (FRP) composite laminates. Int J Mach Tool Manu 35(5):701–771CrossRefGoogle Scholar
  12. 12.
    Davim JP, Reis P (2005) Damage and dimensional precision on milling carbon fiber-reinforced plastics using design experiments. J Mater Process Technol 160(2):160–167CrossRefGoogle Scholar
  13. 13.
    Sheikh-Ahmad J, Urban N, Cheraghi H (2012) Machining damage in edge trimming of CFRP. Mater Manuf Process 27(7):802–808CrossRefGoogle Scholar
  14. 14.
    Chibane H, Morandeau A, Serra R, Bouchou A, Leroy R (2013) Optimal milling conditions for carbon/epoxy composite material using damage and vibration analysis. Int J Adv Manuf Technol 68(5–8):1111–1121CrossRefGoogle Scholar
  15. 15.
    Erkan Ö, Isik B, Cicek A, Kara F (2013) Prediction of damage factor in end milling of glass fibre reinforced plastic composites using artificial neural network. Appl Compos Mater 20(4):517–536CrossRefGoogle Scholar
  16. 16.
    Ghidossi P, El Mansori M, Pierron F (2004) Edge machining effects on the failure of polymer matrix composite coupons. Compos Appl Sci and Manuf 35(7):989–999CrossRefGoogle Scholar
  17. 17.
    Franke V (2011) Drilling of long fiber reinforced thermoplastics—influence of the cutting edge on the machining results. CIRP Ann-Manuf Techn 60(1):65–68CrossRefGoogle Scholar
  18. 18.
    Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tool Manu 49(15):1185–1196CrossRefGoogle Scholar
  19. 19.
    De Lacalle LNL, Lamikiz A, Campa FJ, Valdivielso AF (2009) Design and test of a multitooth tool for CFRP milling. J Compos Mater 43(26):3275–3290CrossRefGoogle Scholar
  20. 20.
    Hosokawa A, Hirose N, Ueda T, Furumoto T (2014) High-quality machining of CFRP with high helix end mill. CIRP Ann-Manuf Techn 63(1):89–92CrossRefGoogle Scholar
  21. 21.
    Hintze W, Marcel C, Gregor K (2015) Influence of weave structure on delamination when milling CFRP. J Mater Process Technol 216:199–205CrossRefGoogle Scholar
  22. 22.
    Gordon S, Hillery MT (2003) A review of the cutting of composite materials. P I Mech Eng L-J MAT 217(1):35–45Google Scholar
  23. 23.
    Zenia S, Ayed LB, Nouari M, Delamézière A (2015) Numerical analysis of the interaction between the cutting forces, induced cutting damage, and machining parameters of CFRP composites. Int J Adv Manuf Technol 78(1–4):465–480CrossRefGoogle Scholar
  24. 24.
    Hintze W, Dirk H, Christoph S (2011) Occurrence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs)—an experimental study. Compos Sci Technol 71(15):1719–1726CrossRefGoogle Scholar
  25. 25.
    Hintze W, Dirk H (2013) Modeling of delamination during milling of unidirectional CFRP. Procedia CIRP 8:444–449CrossRefGoogle Scholar
  26. 26.
    Jahromi AS, Bahr B, Krishnan KK (2014) An analytical method for predicting damage zone in orthogonal machining of unidirectional composites. J Compos Mater 48(27):3355–3365CrossRefGoogle Scholar
  27. 27.
    Niu B, Su YL, Yang R, Jia ZY (2016) Micro-macro-mechanical model and material removal mechanism of machining carbon fiber reinforced polymer. Int J Mach Tool Manu 111:43–54CrossRefGoogle Scholar
  28. 28.
    Wang DH, Ramulu M, Arola D (1995) Orthogonal cutting mechanisms of graphite/epoxy composite. Part I: unidirectional laminate. Int J Mach Tool Manu 35(12):1623–1638CrossRefGoogle Scholar
  29. 29.
    Qi Z, Zhang K, Cheng H, Wang D, Meng Q (2015) Microscopic mechanism based force prediction in orthogonal cutting of unidirectional CFRP. Int J Adv Manuf Technol 79(5–8):1209–1219CrossRefGoogle Scholar
  30. 30.
    Xu W, Zhang L (2016) Mechanics of fibre deformation and fracture in vibration-assisted cutting of unidirectional fibre-reinforced polymer composites. Int J Mach Tool Manu 103:40–52CrossRefGoogle Scholar
  31. 31.
    Li H, Qin X, He G, Jin Y, Sun D, Price M (2016) Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP. Int J Adv Manuf Technol 82(5–8):1079–1088CrossRefGoogle Scholar
  32. 32.
    Johnson K L. 1987 Contact mechanics. Cambridge University PressGoogle Scholar
  33. 33.
    Maegawa S, Morikawa Y, Hayakawa S, Itoigawa F, Nakamura T (2016) Mechanism for changes in cutting forces for down-milling of unidirectional carbon fiber reinforced polymer laminates: modeling and experimentation. Int J Mach Tool Manu 100:7–13CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2017

Authors and Affiliations

  • Fu-ji Wang
    • 1
  • Jun-wei Yin
    • 1
  • Jian-wei Ma
    • 1
    Email author
  • Zhen-yuan Jia
    • 1
  • Fan Yang
    • 1
  • Bin Niu
    • 1
  1. 1.Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, School of Mechanical EngineeringDalian University of TechnologyDalianChina

Personalised recommendations