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Material removal mechanism of UD-C/C composites in ultrasonic-assisted vibration orthogonal cutting

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Abstract

To address the problems of severe machined surface defects and serious material breakage in unidirectional C/C composites (UD-C/C), this study investigates a UD-C/C composite removal mechanism using ultrasonic-assisted orthogonal cutting technology. A solid cemented carbide cutting edge is used. This study focuses on the chip formation, cutting forces, and morphology of the machined surface in different directions between the tool feed and fiber, including perpendicular to the fiber, along the fiber, along the fiber cross section, and different fiber orientation angles, recorded simultaneously using a high-speed camera. The experimental results indicated that, in the perpendicular direction, damage in the interfacial phase and crack extension in the matrix dominated the chip generation process. The cracks formed during cutting along the fiber direction were relatively short, thus producing continuous segmentation chips. Owing to the accumulation and extrusion of chips, the measured cutting force remained low rather than zero. In the fiber direction, the extension of interfacial cracks in the direction of the fiber and the bending fracture of the fiber dominate in the process of material removal. The matrix was first removed, and the fiber was bent and clung to the rank face, producing a continuous band of chips. The measured cutting force remained stable. In the cross-sectional fiber direction, crack propagation results from interlayer separation, fiber yield, and matrix breakage caused by tool extrusion. The cracks expanded along the interface to the inner part of the material, and discontinuous powders were formed during the cutting process. Moreover, for different fiber orientation angles, the machining quality of the acute cutting zone was significantly better than that of the obtuse cutting zone. Second, the surface topographies of the workpieces were evaluated using a 3D surface-measuring instrument and scanning electron microscopy (SEM). Owing to the occurrence of secondary cutting, the quality of surface topographies cutting perpendicular to the fiber direction improves with increasing cutting depths. The surface topographies cutting along the fiber direction present numerous craters on the surface of the specimen as well as regional surface damage. The surface topographies cutting along the fiber cross-sectional direction show relatively serious machining damage and poor surface machining quality.

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Acknowledgements

The authors deeply acknowledge the Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University) and Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (Northwestern Polytechnical University) for providing us with the ability to conduct this research.

Funding

This work was co-supported by the National Natural Science Foundation of China (Nos. 51875473 and 91960203), the Science Center for Gas Turbine Project (P2021-A-IV-003–001), and the Fundamental Research Funds for the Central Universities (D5000230048).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Northwestern Polytechnical University, Ministry of Industry and Information Technology, Xi’an, Shaanxi, 710072, China

    Fangchao Jia, Chenwei Shan, Ziwen Xia, Zixuan Pang & Menghua Zhang

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi’an, Shaanxi, 710072, China

    Fangchao Jia, Chenwei Shan, Ziwen Xia, Zixuan Pang & Menghua Zhang

  3. State Key Laboratory of Cemented Carbide, Zhuzhou, Hunan, 412000, China

    Chenwei Shan

  4. AVIC Xi’an Flight Automatic Control Research Institute, Xi’an, Shaanxi, 710076, China

    Zixuan Pang

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  1. Fangchao Jia
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Contributions

Fangchao Jia: methodology, validation, and writing—original draft; Chenwei Shan: conceptualization, methodology, supervision, funding acquisition, and writing—review and editing; Ziwen Xia: visualization; Zixuan Pang: investigation; and Menghua Zhang: supervision and writing—review and editing.

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Correspondence to Chenwei Shan.

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Jia, F., Shan, C., Xia, Z. et al. Material removal mechanism of UD-C/C composites in ultrasonic-assisted vibration orthogonal cutting. Int J Adv Manuf Technol 130, 851–869 (2024). https://doi.org/10.1007/s00170-023-12776-1

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