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Effect of graphene additive on cutting forces and temperature during the trimming process of CFRP

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Abstract

Carbon fiber-reinforced polymer (CFRP) composite materials are massively used since the last decades in many contemporary applications, especially in aerospace for their strength to density and stiffness to density ratios which are higher than alloys. On the other hand, CFRP are known to be difficult to machine compared to metals due to their heterogeneous and anisotropic structure. Common damages like delamination, fiber loosening and pull out, uncut fibers, and mechanical and thermal damages to the epoxy matrix are observed after machining. This research studies the effect of graphene particles addition in epoxy matrix of CFRP on the cutting temperature, in a global objective of improving the machinability and cutting tool life. Thereby, four modified resin plates (0%wt, 0.25%wt, 3%wt, and 10%wt of graphene) without carbon fibers (nanocomposite plates only) were first molded. Next, three CFRP laminates with different percentages of graphene (0%wt, 0.25%wt, and 3%wt) were manufactured using a combination of vacuum bagging and hydraulic pressing in order to guarantee a good fillers’ distribution within the composite plates and a consistent fiber volume fraction. The trimming experiments were performed using a polycrystalline diamond (PCD) tool which was selected for its well-known machining performance. As expected, the tool wear was nonexistent on nanocomposites. For CFRP plates, the tool wear remained in its break-in zone throughout the experiment (final Vb \(\approx 0.051\ll 0.3 \mathrm{mm}\) for a final length cut of 4.5 m). The cutting tool’s temperature increases with graphene concentration for both nanocomposites and CFRP samples. However, the temperature increase of CFRP plates was reduced by 30% with a graphene concentration of 3%wt. The feed forces were also greatly reduced (up to 43%) with graphene when machining CFRP.

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Funding

This research was funded by the National Research Council of Canada (NSERC grant NSERC EGP534389-18) and NanoXplore Inc.

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Authors and Affiliations

  1. École de Technologie Supérieure, 1100 Notre Dame West, Montreal, QC, H3C 1K3, Canada

    Ronan Mathieu, Mohamed Ali Charfi, Jean-Francois Chatelain & Claudiane Ouellet-Plamondon

  2. INSA Centre Val de Loire, 3 Rue de la Chocolaterie, 41000, Blois, France

    Roger Serra

  3. Université du Québec À Trois-Rivières, 3351 Boulevard des Forges, Trois-Rivières, QC, G8Z 4M3, Canada

    Gilbert Lebrun

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  1. Ronan Mathieu
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Correspondence to Jean-Francois Chatelain.

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Mathieu, R., Charfi, M.A., Chatelain, JF. et al. Effect of graphene additive on cutting forces and temperature during the trimming process of CFRP. Int J Adv Manuf Technol 122, 3969–3981 (2022). https://doi.org/10.1007/s00170-022-10150-1

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