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Study of the surface quality of carbon fiber–reinforced thermoplastic matrix composite (CFRTP) machined by abrasive water jet (AWJM)

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Abstract

Carbon fiber-reinforced thermoplastics (CFRTP) have great interest nowadays due to their excellent mechanical properties and lightness. However, in opposition to thermoset matrix composites, there is a lake in the research about machining processes of these materials. Their low glass transition temperature is a handicap when conventional machining is used. An alternative is abrasive water jet machining (AWJM) because it does not cause thermal damage. However, the surface quality produced by this process must be studied and related to the cutting parameters. This article studies the surface quality generated by water jet machining in a low melting point thermoplastic matrix composite material. The kind of thermoplastic used is a TPU (polyurethane). The combination of a high-strength material (carbon fiber) with a low-strength material (thermoplastic matrix) makes machining difficult and can generate a poor surface finish. The influence of cutting parameters has been evaluated through an ANOVA analysis. A mathematical model that relates the surface quality with the cutting parameters has been established by means of a response surface methodology (RSM). The combination of a hydraulic pressure of 250 MPa with a traverse speed of 300 mm/min and an abrasive mass flow of 170 g/min produces the best surface quality. Finally, the main flaws when CFRTP is water jet machined have also been identified.

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Abbreviations

\( \dot{m} \) a :

abrasive mass flow

ANOVA:

analysis of variance

AWJM:

abrasive water jet machining

CFRP:

carbon fiber-reinforced plastics with thermoset matrix

CFRTP:

carbon fiber-reinforced thermoplastics

EAZ:

erosion affected zone

EDS:

energy-dispersive X-ray spectroscopy

P :

hydraulic pressure

Ra:

arithmetic mean roughness

RSM:

response surface methodology

SEM:

scanning electron microscope

TPU:

thermoplastic polyurethane

UFFD:

ultrafast feed drilling

UVD:

ultrasonic vibration-assisted drilling

v :

traverse speed

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Funding

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

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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

    Fermin Bañon, Alejandro Sambruno, Moises Batista & Jorge Salguero

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

    Bartolome Simonet

Authors
  1. Fermin Bañon
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  2. Alejandro Sambruno
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  3. Moises Batista
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  4. Bartolome Simonet
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  5. Jorge Salguero
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Contributions

F.B. and A.S. 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.

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Correspondence to Fermin Bañon.

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Bañon, F., Sambruno, A., Batista, M. et al. Study of the surface quality of carbon fiber–reinforced thermoplastic matrix composite (CFRTP) machined by abrasive water jet (AWJM). Int J Adv Manuf Technol 107, 3299–3313 (2020). https://doi.org/10.1007/s00170-020-05215-y

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