Skip to main content
SpringerLink
Log in

Surface quality evaluation for CFRP milling and its impact on the mechanical properties

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

Abstract

Wide applications of carbon fiber–reinforced polymer (CFRP) components in modern manufacturing enterprises have led to significant demand in the secondary machining processes. However, the machining surface quality characterization and its impact on the material’s mechanical performance are not fully investigated. In this paper, a quantitative characterization method is proposed for assessing CFRP milling surface quality by combining SEM and image segmentation techniques, which was evaluated using three indices, namely, surface roughness, surface void fraction, and depth of affected zone. Finite element simulation and experiments about side milling of unidirectional CFRP with 90° fiber orientation were conducted to investigate the effects of milling conditions on the resulting surface quality indices. It was found that feed rate and cutting edge radius are two dominant factors that affect the surface void and the depth of affected zone, and the down-milling style is accompanied by greater machining damages due to the difference fiber cutting angle compared with up-milling. Meanwhile, the influence of the above three indices on the tensile and compressive strength of CFRP specimen was also obtained. It is concluded that the depth of the affected zone has a more significant effect on the strength degradation of machined CFRP materials.

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
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

Code availability

Not applicable.

References

  1. Das TK, Ghosh P, Das NC (2019) Preparation, development, outcomes, and application versatility of carbon fiber-based polymer composites: a review. Adv Compos Hybrid Mater 1–20

  2. Ben Soussia A, Mkaddem A, El Mansori M (2014) Rigorous treatment of dry cutting of frp – interface consumption concept: a review. Int J Mech Sci 83:1–29

    Article  Google Scholar 

  3. Seo J, Kim DY, Kim DC et al (2021) Recent developments and challenges on machining of carbon fiber reinforced polymer composite laminates. Int J Precis Eng Manuf 22(12):2027–2044

    Article  Google Scholar 

  4. Geier N, Xu J, Pereszlai C et al (2021) Drilling of carbon fibre reinforced polymer (CFRP) composites: difficulties, challenges and expectations. Procedia Manuf 54(6):284–289

    Article  Google Scholar 

  5. 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 A Appl Sci Manuf 66:142–154

    Article  Google Scholar 

  6. Chen Y, Guo X, Zhang K et al (2019) Study on the surface quality of CFRP machined by micro-textured milling tools. J Manuf Process 37(JAN.):114–123

    Article  Google Scholar 

  7. Wang C, Liu G, An Q, Chen M (2017) Occurrence and formation mechanism of surface cavity defects during orthogonal milling of CFRP laminates. Compos Part B Eng 109:10–22

    Article  Google Scholar 

  8. El-Hofy MH, Soo SL, Aspinwall DK, Sim WM, Pearson D, Harden P (2011) Factors affecting workpiece surface integrity in slotting of CFRP. Procedia Eng 19:94–99

    Article  Google Scholar 

  9. Geier N (2020) Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites. Int J Adv Manuf Technol 111(3):881–893

    Article  Google Scholar 

  10. Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tools Manuf 49(15):1185–1196

    Article  Google Scholar 

  11. Zitoune R, Krishnaraj V, Almabouacif BS, Collombet F, Sima M, Jolin A (2012) Influence of machining parameters and new nano-coated tool on drilling performance of CFRP/Aluminium sandwich. Compos B Eng 43(3):1480–1488

    Article  Google Scholar 

  12. Wang C, Liu G, An Q et al (2017) Occurrence and formation mechanism of surface cavity defects during orthogonal milling of CFRP laminates. Compos Part B Eng 109(Jan.):10–22

    Google Scholar 

  13. Kumar D, Gururaja S (2020) Machining damage and surface integrity evaluation during milling of UD-CFRP laminates: Dry vs Cryogenic. Compos Struct 247:112504

    Article  Google Scholar 

  14. Geier N, Poór DI, Pereszlai C et al (2022) Drilling of recycled carbon fibre–reinforced polymer (rCFRP) composites: analysis of burrs and microstructure. Int J Adv Manuf Technol 1–17

  15. Alberdi A, Suárez A, Artaza T, Escobar-Palafox GA, Ridgway K (2013) Composite cutting with abrasive water jet. Procedia Eng 63(63):421–429

    Article  Google Scholar 

  16. Shyha I (2013) An investigation into CO2 laser trimming of CFRP and GFRP composites. Procedia Eng 63:931–937

    Article  Google Scholar 

  17. Geier N, Pereszlai C (2020) Analysis of characteristics of surface roughness of machined CFRP composites. Period Polytech Mech Eng 64(1):67–80

    Article  Google Scholar 

  18. 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 B Eng 57:136–143

    Article  Google Scholar 

  19. Pecat O, Rentsch R, Brinksmeier E (2012) Influence of milling process parameters on the surface integrity of CFRP. Procedia CIRP 1:466–470

    Article  Google Scholar 

  20. Cheng H, Gao J, Kafka OL et al (2017) A micro-scale cutting model for UD CFRP composites with thermo-mechanical coupling. Compos Sci Technol 153:18–31

    Article  Google Scholar 

  21. Abena A, Essa K (2019) 3D micro-mechanical modelling of orthogonal cutting of UD-CFRP using smoothed particle hydrodynamics and finite element methods. Compos Struct 218:174–192

    Article  Google Scholar 

  22. Yan X, Reiner J, Bacca M et al (2019) A study of energy dissipating mechanisms in orthogonal cutting of UD-CFRP composites. Compos Struct 220:460–472

    Article  Google Scholar 

  23. Jiang H, Ren Y, Liu Z (2019) Micro-and macro-scale simulation for axial cutting machining behaviors of 2D tri-axially braided composites. Int J Mech Sci 156:1–13

    Article  Google Scholar 

  24. Rong C, Shujian L, Pengnan L et al (2020) Effect of fiber orientation angles on the material removal behavior of CFRP during cutting process by multi-scale characterization. Int J Adv Manuf Technol 106(11):5017–5031

    Article  Google Scholar 

  25. Wang F, Wang X, Yang R et al (2017) Research on the carbon fibre-reinforced plastic (CFRP) cutting mechanism using macroscopic and microscopic numerical simulations. J Reinf Plast Compos 36(8):555–562

    Article  Google Scholar 

  26. Petropoulos GP, Pandazaras CN, Davim JP (2010) Surface integrity in machining. Springer London

  27. Astakhov VP (2010) Surface integrity–definition and importance in functional performance. Springer London

  28. Li H, Qin X, He G, Price MA, Jin Y, Sun D (2017) An energy based force prediction method for UD-CFRP orthogonal machining. Compos Struct 159:34–43

    Article  Google Scholar 

  29. Xu W, Zhang LC (2014) On the mechanics and material removal mechanisms of vibration-assisted cutting of unidirectional fibre-reinforced polymer composites. Int J Mach Tools Manuf 80–81:1–10

    Article  Google Scholar 

  30. Su Y (2019) Effect of the cutting speed on the cutting mechanism in machining CFRP. Compos Struct 220:662–676

    Article  Google Scholar 

  31. Masek P, Kolar P, Zeman P (2013) Optimization of trimming operations for machining carbon fibre reinforced thermoplastic composite. Int Conf Adv Manuf Eng Technol Newtech

  32. Alauddin M, Mazid MA, Baradi MAE, Hashmi MSJ (1998) Cutting forces in the end milling of Inconel 718. J Mater Process Technol 77(3):153–159

    Article  Google Scholar 

  33. Saleem M, Zitoune R, Sawi IE, Bougherara H (2015) Role of the surface quality on the mechanical behavior of cfrp bolted composite joints. Int J Fatigue 80:246–256

    Article  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (Grant numbers: 51775373, and 52075380), and the Natural Science Foundation of Tianjin (Grant number: 19JCYBJC19000).

Author information

Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Jinnan District, No. 135 Yaguan Rd, Tianjin, 300354, People’s Republic of China

    Xuda Qin, Zhengwei Bao, Weizhou Wu, Hao Li, Shipeng Li & Qing Zhao

Authors
  1. Xuda Qin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhengwei Bao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Weizhou Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hao Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Shipeng Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Qing Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Xuda Qin: investigation, experimental design, data analysis, writing, and editing. Zhengwei Bao: finite element model, numerical and experimental data analysis, writing, and editing. Weizhou Wu: investigation, preparation of experimental materials, review, and editing. Hao Li: investigation, preparation of experimental materials, review, and editing. Shipeng Li: review and editing. Qing Zhao: review and editing.

Corresponding author

Correspondence to Hao Li.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Competing interests

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

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Qin, X., Bao, Z., Wu, W. et al. Surface quality evaluation for CFRP milling and its impact on the mechanical properties. Int J Adv Manuf Technol 122, 1083–1097 (2022). https://doi.org/10.1007/s00170-022-09942-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09942-2

Keywords

Search

Navigation