Skip to main content
SpringerLink
Log in

Development of cutting force prediction model for vibration-assisted slot milling of carbon fiber reinforced polymers

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

Abstract

Carbon fiber reinforced polymers (CFRP) have got rapidly increased applications in aerospace/aircraft and other fields due to their attractive properties of high specific strength/stiffness, high corrosion resistance, and low thermal expansion. These materials have also some challenging properties like heterogeneity, anisotropy, and low heat dissipation. Due to these properties, the issues of excessive cutting forces and machining damages (delamination, fiber pull-out, surface/subsurface defects, etc.) are encountered in machining. The cutting forces are required to be minimized for qualified machining with reduced damages. In this research, a novel cutting force prediction model has been developed for vibration-assisted slot milling. The experimental machining has been carried out on CFRP-T700 composite material. The effective cutting time per vibration cycle and the force of friction have been expressed/calculated. The feasibility of vibration-assisted machining for CFRP composites has also been evaluated. The relationships of the axial and feed cutting forces with machining parameters were investigated. The results have shown the variations below 10% among experimental and corresponding simulation values (from the model) of cutting forces. However, the higher variations have been found in some experiments which are mainly due to heterogeneity, anisotropy, and some other properties of such materials. The developed cutting force model then validated through pilot experiments and found the same results. So, the developed cutting force model is robust and can be applied to predict cutting forces and optimization for vibration-assisted slot milling of CFRP composite materials at the industry level.

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

Similar content being viewed by others

References

  1. Jones RM (1999) Mechanics of composite materials, 2nd edn. Taylor & Francis Inc, Philadelphia

    Google Scholar 

  2. Kaw AK (2006) Mechanics of composite materials, 2nd edn. Taylor & Francis Group, Florida

    MATH  Google Scholar 

  3. Walz M (2006) The dream of composites. www.rdmag.com. Accessed 5 Jan 2017

  4. Saoubi RM, Axinte D, Soo LS, Nobel C, Attia H, Kappmeyer G, Engin S, Sim W (2015) High performance cutting of advanced aerospace alloys and composite materials. CIRP Ann Manuf Technol 64:577–580

    Article  Google Scholar 

  5. Ashby MF, Bush SF, Swindells N, Bullough R, Ellison G, Lindblom Y, Cahn RW, Barnes JF (1987) Technology of the 1990s: advanced materials and predictive design [and discussion]. Phil Trans R Soc Land A 322(1567):393–407

    Article  Google Scholar 

  6. Sheikh-Ahmad JY (2009) Machining of polymer composites. Springer Science, New York. https://doi.org/10.1007/978-0-387-68619-6

    Book  Google Scholar 

  7. Liu JW, Baek DK, Ko TJ (2014) Chipping minimization in drilling ceramic materials with rotary ultrasonic machining. J Adv Manuf Technol 72(9–12):187–190

    Google Scholar 

  8. Kalla D, Sheikh-Ahmad J, Twomey J (2010) Prediction of cutting forces in helical end milling of fiber reinforced polymers. Int J Mach Tools Manuf 50:882–891

    Article  Google Scholar 

  9. Chen ST, Jiang ZH, Wu YY, Yang HY (2011) Development of a grinding–drilling technique for holing optical grade glass. Int J Mach Tools Manuf 51(2):95–103

    Article  Google Scholar 

  10. Groover MP (2010) Fundamental of modern manufacturing: materials, processes, and systems, 4th edn. Wiley & Sons Inc, USA

    Google Scholar 

  11. Xu W, Zhang LC, Wub Y (2014) Elliptic vibration-assisted cutting of fiber-reinforced polymer composites: understanding the material removal mechanisms. J Compos Sci Technol 92:103–111

    Article  Google Scholar 

  12. Pei ZP, Ferreira PM, Haselkorn M (1995) Plastic flow in rotary ultrasonic machining of ceramics. J Mater Process Technol 48(1):771–777

    Article  Google Scholar 

  13. Lau WS, Wang M, Lee WB (1990) Electric discharge machining of carbon fibre composite materials. Int J Mach Tools Manuf 30(2):297–308

    Article  Google Scholar 

  14. Alberadi A, Artaza T, Suarez A, Rivero A, Girot F (2016) An experimental study on abrasive water jet cutting on CFRP/TiA14V stacks for drilling operations. Int J Adv Manuf Technol 86:691–704

    Article  Google Scholar 

  15. Singh RP, Singhal S (2016) Rotary ultrasonic machining: a review. J Mater Manuf Process 31:1795–1824

    Article  Google Scholar 

  16. Thoe TB, Aspinwall DK, Wise MLH (1998) Review on ultrasonic machining. Int J Mach Tools Manuf 38(4):239–255

    Article  Google Scholar 

  17. Kataria R, Kumar J, Pabla BS (2016) Experimental investigation and optimization of machining characteristics in ultrasonic machining of WC-Co composite using GRA method. J Mater Manuf Process 31:685–693

    Article  Google Scholar 

  18. Halm R, Schulz P (1993) Ultrasonic machining of complex ceramic components. Erosion AC Report, DKG 70 70 (6):6–13

  19. Gilmore R (1991) Ultrasonic machining–a case study. J Mater Process Technol 28(1–2):139–148

    Article  Google Scholar 

  20. Moriwaki T, Shamoto E, Inoue K (1991) Ultraprecision ductile cutting of glass by applying ultrasonic vibration. CIRP Ann Manuf Technol 41(1):559–562

    Article  Google Scholar 

  21. Isaev A, Anokhin V (1961) Ultrasonic vibration of a metal cutting tool. Vest Mashinos 41 (Translation from Russian)

  22. Zhang SSF, Bone GM (2009) Thrust force model for vibration-assisted drilling of aluminum 6061-T6. Int J Mach Tools Manuf 49:1070–1076

    Article  Google Scholar 

  23. Makhdum F, Jennings LT, Roy A, Silberschmidt VV (2012) Cutting forces in ultrasonically asssited drilling of carbon fiber reinforced plastics. J Phys Conf Ser 382:12–19. https://doi.org/10.1088/1742-6596/382/1/012019

    Google Scholar 

  24. Phadnis VA, Makhdum F, Roy A, Silberschmidt VV (2012) Experimental and numerical investigations in conventional and ultrasonically assisted drilling of CFRP laminates. Procedia CIRP 1:455–459

    Article  Google Scholar 

  25. Mehbudi P, Baghlani V, Akbari J, Bushrao AR, Mardi NA (2013) Applying ultrasonic vibration to decrease drilling-induced delamination in GFRP laminates. Procedia CIRP 6:577–582

    Article  Google Scholar 

  26. Ladonne M, Cherif M, Landon Y, Navez JK, Cahuc O, Castelbajac CD (2015) Modelling the vibration-assisted drilling process: identification of influential phenomena. Int J Adv Manuf Technol 81:1657–1666

    Article  Google Scholar 

  27. Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32(3):153–172

    Article  Google Scholar 

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

    Article  Google Scholar 

  29. Hua ZJ, Yan Z, Qiang TF, Shuo Z, Shen GL (2015) Kinematics and experimental study on ultrasonic vibration-assisted micro end grinding of silica glass. Int J Adv Manuf Technol 78:1893–1904

    Article  Google Scholar 

  30. Ding H, Chen SJ, Cheng K (2010) Two-dimensional vibration-assisted micro end milling: cutting force modelling and machining process dynamics. Proc IMechE B J Eng Manuf 224:1775–1783

    Article  Google Scholar 

  31. Tao G, Ma C, Shen X, Zhang J (2017) Experimental and modeling study on cutting forces of feed direction ultrasonic vibration-assisted milling. Int J Adv Manuf Technol 90:709–715

    Article  Google Scholar 

  32. Ostasevicius V, Gaidys R, Dauksevicius R, Mikuckyte S (2013) Study of vibration milling for improving surface finish of difficult-to-cut materials. J Mech Eng 59(6):351–357

    Article  Google Scholar 

  33. Zemann R, Kain L, Bleicher F (2014) Vibration assisted machining of carbon fibre reinforced polymers. In: 24th DAAAM International symposium on intelligent manufacturing and automation, 2013. Procedia Eng, pp 536–543

  34. Kumar MN, Subbu SK, Krishn PV, Venugopal A (2014) Vibration assisted conventional and advanced machining: a review. Procedia Eng 97:1577–1586

    Article  Google Scholar 

  35. Marcel K, Marek Z, Jozef P (2014) Invesigation of ultrasonic assisted milling of aluminium alloy AlMg4.5Mn. In: 24th DAAAM International symposium on intelligent manufacturing and automation, 2013. Procedia Eng, pp 1048–1053

  36. Lin SY, Kuan CH, She CH, Wang WT (2015) Application of ultrasonic assisted machining technique for glass-ceramic milling. Int J Mech Aerosp Ind Mechatron Manuf Eng 9(5):802–807

    Google Scholar 

  37. Ibrahim R, Rafai NH, Rahim EA, Ceng K, Ding H (2015) A performance of 2 dimensional ultrasonic vibration assisted milling in cutting force reduction, on Aluminium AL6061. ARPN J Eng Appl Sci 11(18):11124–11128

    Google Scholar 

  38. Zarchi MMA, Razfar MR, Abdullah A (2013) Influence of ultrasonic vibrations on side milling of AISI 420 stainless steel. Int J Adv Manuf Technol 66:83–89

    Article  Google Scholar 

  39. Nath C, Rehman M (2008) Effective of machining parameters in ultrasonic vibration cutting. Int J Mach Tools Manuf 48(9):965–974

    Article  Google Scholar 

  40. Mondelin A, Furet B, Rech J (2010) Characterisation of friction properties between a laminated carbon fibers reinforced polymer and a monocrystalline diamond under dry or lubricated conditions. J Tribol Int 43:1665–1673

    Article  Google Scholar 

  41. Yuan S, Zhang C, Amin M, Fan H, Liu M (2015) Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling. Int J Adv Manuf Technol 81:1223–1231. https://doi.org/10.1007/s00170-015-7269-x

    Article  Google Scholar 

  42. Least square method. https://en.wikiversity.org/wiki/Least-squares_Method. Accessed 15 Mar 2015

Download references

Acknowledgements

This research is financially supported by National High Technology Research and Development Program of China under program no. 863 with grant no.2013AA040105. The authors are indebted to this financial support to accomplish this research work.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering & Automation, Beijing Engineering Technological Research Center of High-efficient & Green CNC Machining Process and Equipment, Beihang University, Beijing, 100191, China

    Muhammad Amin, Songmei Yuan, Li Zhen & Wu Qi

  2. Department of Mechanical Engineering, Institute of Space Technology, Islamabad, Pakistan

    Muhammad Amin & Asif Israr

Authors
  1. Muhammad Amin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Songmei Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Asif Israr
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Li Zhen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wu Qi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Songmei Yuan.

Electronic supplementary material

(MP4 28,138 kb)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Amin, M., Yuan, S., Israr, A. et al. Development of cutting force prediction model for vibration-assisted slot milling of carbon fiber reinforced polymers. Int J Adv Manuf Technol 94, 3863–3874 (2018). https://doi.org/10.1007/s00170-017-1087-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1087-2

Keywords

Search

Navigation