Abstract
Although FRPs are usually fabricated to near net shapes after curing, post-machining operations are necessary to assure that the composite parts meet dimensional tolerance, surface quality and other functional requirements. Owing to the material’s unique anisotropic characteristics, it is a challenge to machine FRPs without machining damage. Machining damages can arise in each phase of the material, including matrix cracking, fibre fracture, fibre pull-out, fibre-matrix debonding and delamination. Orthogonal cutting is a common machining process for better understanding of the mechanisms of common processing methods. Traditional machining operations, such as turning, milling and drilling, are still the primary processing mode of FRPs. With considerations to processing demands and material performance of different composite materials, developing the corresponding special cutter is the key technology to prolong the cutter’s service life and improve processing quality.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Geng, D., Liu, Y., Shao, Z., Lu, Z., Cai, J., Li, X., Jiang, X., Zhang, D.: Delamination formation, evaluation and suppression during drilling of composite laminates: a review. Compos. Struct. 216, 168–186 (2019)
Rawat, S., Attia, H.: Wear mechanisms and tool life management of WC-Co drills during dry high speed drilling of woven carbon fibre composites. Wear 267(5–8), 1022–1030 (2009)
Freeman, W.-T., Kuebeler, G.-C.: Composite Materials: Testing and Design (Third Conference). ASTM International (1974)
Chatterjee, A.: Thermal degradation analysis of thermoset resins. J. Appl. Polym. Sci. 114(3), 1417–1425 (2009)
Selzer, R., Friedrich, K.: Mechanical properties and failure behaviour of carbon fibre-reinforced polymer composites under the influence of moisture. Compos. Part A 28(6), 595–604 (1997)
König, W., Graß, P.: Quality definition and assessment in drilling of fibre reinforced thermosets. CIRP Ann. Manuf. Technol. 38(1), 119–124 (1989)
Xu, W., Zhang, L.: Tool wear and its effect on the surface integrity in the machining of fibre-reinforced polymer composites. Compos. Struct. 188, 257–265 (2018)
Stone, R., Krishnamurthy, K.: A neural network thrust force controller to minimize delamination during drilling of graphite-epoxy laminates. Int. J. Mach. Tools Manuf. 36(9), 985–1003 (1996)
Li, H., Qin, X., He, G., Price. M.-A., Jin, Y., Sun, D.: An energy based force prediction method for UD-CFRP orthogonal machining. Compos. Struct. 159, 34–43 (2017)
An, Q., Cai, C., Cai, X., Chen, M.: Experimental investigation on the cutting mechanism and surface generation in orthogonal cutting of UD-CFRP laminates. Compos. Struct. 230, 111441 (2019)
Liu, D., Tang, Y., Cong, W.-L.: A review of mechanical drilling for composite laminates. Compos. Struct. 94(4), 1265–1279 (2012)
Vasudevan, H., Rajguru, R., Tank, K., Shetty, N.: Optimization of multi-performance characteristics in the turning of GFRP(E) composites using principle component analysis combined with grey relational analysis. Mater. Today Proc. 5(2), 5955–5967 (2018)
Davim, J.-P., Mata, F.: A new machinability index in turning fiber reinforced plastics. J. Mater. Process. Technol. 170(1–2), 436–440 (2005)
Henerichs, M., Voß, R., Kuster, F., Wegener, K.: Machining of carbon fiber reinforced plastics: influence of tool geometry and fiber orientation on the machining forces. CIRP J. Manuf. Sci. Technol. 9, 136–145 (2015)
Rajasekaran, T., Palanikumar, K., Vinayagam, B.-K.: Application of fuzzy logic for modeling surface roughness in turning CFRP composites using CBN tool. Prod. Eng. 5(2), 191–199 (2011)
Sivasankaran, S., Harisagar, P.-T., Saminathan, E., Siddharth, S., Sasikumar, P.: Effect of process parameters in surface roughness during turning of GFRP pipes using PCD insert tool. Procedia Eng. 97, 64–71 (2014)
Hou, G., Zhang, K., Fan, X., Luo, B., Cheng, H., Yan, X., Li, Y.: Analysis of exit-ply temperature characteristics and their effects on occurrence of exit-ply damages during UD CFRP drilling. Compos. Struct. 231, 111456 (2020)
Fu, R., Jia, Z., Wang, F., Jin, Y., Sun, D., Yang, L., Cheng, D.: Drill-exit temperature characteristics in drilling of UD and MD CFRP composites based on infrared thermography. Int. J. Mach. Tools Manuf. 135, 24–37 (2018)
Su, F., Zheng, L., Sun, F., Wang, Z., Deng, Z., Qiu, X.: Novel drill bit based on the step-control scheme for reducing the CFRP delamination. J. Mater. Process. Technol. 262, 157–167 (2018)
Hrechuk, A., Bushlya, V., Ståhl, J.-E.: Hole-quality evaluation in drilling fiber-reinforced composites. Compos. Struct. 204, 378–387 (2018)
Persson, E., Eriksson, I., Zackrisson, L.: Effects of hole machining defects on strength and fatigue life of composite laminates. Compos. Part A Appl. Sci. Manuf. 28(2), 141–151 (1997)
Ho-Cheng, H., Dharan, C.K.H.: Delamination during drilling in composite laminates. J. Eng. Ind. (Trans. ASME) 112(3), 236–239 (1990)
Wang, B., Yang, B., Wang, M., Zheng, Y., Hong, X., Zhang, F.: Effect of cutting temperature on bending properties of carbon fibre reinforced plastics. Sci. Eng. Compos. Mater. 26(1), 394–401 (2019)
Shyha, I.-S., Aspinwall, D.-K., Soo, S.-L., Bradley, S.: Drill geometry and operating effects when cutting small diameter holes in CFRP. Int. J. Mach. Tools Manuf. 49(12–13), 1008–1014 (2009)
Shyha, I.-S., Soo, S.-L., Aspinwall, D.-K., Bradley, S., Perry, R., Harden, P., Dawson, S.: Hole quality assessment following drilling of metallic-composite stacks. Int. J. Mach. Tools Manuf. 51(7–8), 569–578 (2011)
Wang, B., Wang, Y., Zhao, H., Sun, L., Wang, M., Kong, X.: Effect of a Ti alloy layer on CFRP hole quality during helical milling of CFRP/Ti laminate. Compos. Struct. 252, 112670 (2020)
Wang, C., Liu, G., An, Q., Chen, M.: Occurrence and formation mechanism of surface cavity defects during orthogonal milling of CFRP laminates. Compos. Part B Eng. 109, 10–22 (2017)
Hocheng, H., Tsao, C.-C.: Effects of special drill bits on drilling-induced delamination of composite materials. Int. J. Mach. Tools Manuf. 46(12–13), 1403–1416 (2006)
Jia, Z., Zhang, C., Wang, F., Fu, R., Chen, C.: An investigation of the effects of step drill geometry on drilling induced delamination and burr of Ti/CFRP stacks. Compos. Struct. 235, 111786 (2020)
Wang, F., Qian, B., Jia, Z., Fu, R., Cheng, D.: Secondary cutting edge wear of one-shot drill bit in drilling CFRP and its impact on hole quality. Compos. Struct. 178, 341–352 (2017)
Jain, S., Yang, D.-C.-H.: Delamination-free drilling of composite laminates. J. Eng. Ind. 116(4) (1994)
Tsao, C.-C., Hocheng, H.: Parametric study on thrust force of core drill. J. Mater. Process. Technol. 192–193, 37–40 (2007)
Tsao, C.-C.: Investigation into the effects of drilling parameters on delamination by various step-core drills. J. Mater. Process. Technol. 206(1–3), 405–411 (2008)
Acknowledgements
The editors would like to thank all the contributors (especially to Quan Wen from Northeastern University in China), who participated in scholarship and a desire to help in their busy schedules. This research is also supported by the National Natural Science Foundation of China (Grant No. 51875367).
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2021 Springer Nature Switzerland AG
About this chapter
Cite this chapter
Wang, B., Gao, H. (2021). Conventional Machining Processes of Fibre Reinforced Polymer Composites. In: Shyha, I., Huo, D. (eds) Advances in Machining of Composite Materials. Engineering Materials. Springer, Cham. https://doi.org/10.1007/978-3-030-71438-3_3
Download citation
DOI: https://doi.org/10.1007/978-3-030-71438-3_3
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-71437-6
Online ISBN: 978-3-030-71438-3
eBook Packages: EngineeringEngineering (R0)