A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

[EN] Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.This research was funded by the Ministry of economy, Industry and Competitiveness and FEDER (grant number: DPI2017-89197-C2-1-R).Criado, V.; Feito-Sánchez, N.; Cantero Guisández, J.; Díaz-Álvarez, J. (2019). A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds. Materials. 12(24):1-13. https://doi.org/10.3390/ma12244074S1131224Che, D., Saxena, I., Han, P., Guo, P., & Ehmann, K. F. (2014). Machining of Carbon Fiber Reinforced Plastics/Polymers: A Literature Review. Journal of Manufacturing Science and Engineering, 136(3). doi:10.1115/1.4026526Vigneshwaran, S., Uthayakumar, M., & Arumugaprabu, V. (2018). Review on Machinability of Fiber Reinforced Polymers: A Drilling Approach. Silicon, 10(5), 2295-2305. doi:10.1007/s12633-018-9764-9Panchagnula, K. K., & Palaniyandi, K. (2018). 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Advanced cutting tools and technologies for drilling carbon fibre reinforced polymer (CFRP) composites: a review

Carbon fibre reinforced polymer (CFRP) composites have excellent specific mechanical properties, these materials are therefore widely used in high-tech industries like the automobile and aerospace sectors. The mechanical machining of CFRP composites is often necessary to meet dimensional or assembly-related requirements; however, the machining of these materials is difficult. In an attempt to explore this issue, the main objective of the present paper is to review those advanced cutting tools and technologies that are used for drilling carbon fibre reinforced polymer composites. In this context, this paper gives a detailed review and discussion of the following: (i) the machinability of CFRP including chip removal mechanisms, cutting force, tool wear, surface roughness, delamination and the characteristics of uncut fibres; (ii) cutting tool requirements for CFRP machining; and (iii) recent industrial solutions: advanced edge geometries of cutting tools, coatings and technologies. In conclusion, it can be stated that advanced geometry cutting tools are often necessary in order to effectively and appropriately machine required quality features when working with CFRP composites.publishe

CFRP-Metal ??????????????? ????????? ??????????????? ?????? ????????? ??? ????????? ??????

Department of Mehcanical EngineeringIn the present study, researchers are more focused on aerospace and automotive fields, however, in this field very difficult task to reduce the inertia of the bodies through a lightweight material with high strength. To reduce this problem, researchers are focused on the CFRP due to its lightweight and its high strength. Carbon fiber reinforced plastic (CFRP) is superior in weight to strength ratio as compared to metal. It is moreover excellent in abrasion resistance and heat resistance. For this reason, CFRP is being used as a functional component material in the transportation industry and automobile industry. Despite the many advantages of CFRP, CFRP is vulnerable to impact and brittle than metal. The main issues during composite materials processing are delamination. The delamination significantly reduces assembly tolerance and strength against fatigue, which reduces the long-term performance of the composite. The size of the delamination zone is related to the thrust force generated in the drilling process, a critical thrust force is generated which does not cause damage. Therefore, several studies have investigated delamination during the drilling process. In this study, numerical models are used to predict thrust force and internal defects in the CFRP-Al stacks drilling process. The physical model is used to generate the mechanism of the thrust force by using the chisel edge and a lip region of the tool, to create a prediction model. The thrust force in the CFRP-Al stack was predicted by the thrust force measured at each part of the tool. FE model (ABAQUS/ Explicit) is used for the prediction of thrust force in the delamination drilling simulation. In the delamination of the material, seven layers of CFRP and one layer of aluminum is used to identify the internal defects in each layer. To represent the multi-direction CFRP, CFRP consisting of 7 layers was modelled at 0 ?? and 90 ??. In this simulation process two damage model are used for defining the material property of the materials. First one is the Hashin???s damage model, used for defining the property of the CFRP material. The second one is the Johnson-cook model, used for defining the property of the aluminum because it represents the internal defects and CFRP-Al stack expressed through cohesive conditions. Moreover, stress contour has been confirmed during CFRP-Al stack drilling simulation. To validate the numerical model, thrust force and machinability were investigated by CFRP-Al stack drilling process and in this process identified the internal defect which is compared by CT scan. Based on the developed prediction model, it is considered that the optimal machining conditions have been derived in the CFRP-Al stack drilling process.ope

Prediction of cutting forces and delamination during carbon fiber reinforced plastics (CFRP) machining

Department of Mechanical EngineeringCarbon Fiber Reinforced Plastic (CFRP) has been widely used in various industrial areas due to its corrosion resistance, stiffness and high strength-to-weight ratio. However, the machining process of CFRP composite material is complex compared to that of metals. The reason is the unique properties of CFRP composite, such as anisotropy and inhomogeneous characteristics. Therefore, many defects, such as uncut fiber, delamination and tool wear, occur in the process of CFRP machining. To prevent defects in CFRP machining, we discuss important factors, cutting mechanism and chip formation. Based on these, numerical models are suggested for cutting forces and damage prediction. It will help optimize machinability and productivity of CFRP machining. In this study, we developed numerical solutions to predict cutting forces along the fiber orientation in each machining condition in CFRP orthogonal cutting. There are preliminary force prediction model and force prediction model according to varying fiber orientation. The first one is from Bhatnagar???s CFRP force prediction model. This model is proved with CFRP orthogonal cutting in each fiber orientation. This model shows that cutting force and thrust force are increased as increasing feed rate similar to the experimental results. High feed rate can increase the depth of cut in machining. This developed model is more accurate than Bhatnagar???s model in wider area in the condition of high feed rate. The reason is that epoxy region contained in preliminary force prediction model rises in wider area. The other model is modified force prediction model for varying fiber orientation. This model was expanded from Zhang???s CFRP force model. Zhang commented this cutting mechanism can be applied only in fiber orientation below 90??. He proved this in low speed CFRP cutting experiments. We did CFRP orthogonal cutting in high cutting speed over 80m/min. We applied similar cutting mechanism into modified model along all the fiber orientation from 0?? to 180??. Force prediction model for all the fiber orientations has similar tendency as the experimental results. The prediction credibility is from 50% to 98.5%. Errors can be generated by many factors in CFRP machining. From this modified force prediction model for varying fiber orientation, damage prediction model can be suggested referring to Jahromi???s damage prediction model. It is based on energy balance in each fiber material. This damage prediction model has similar curve tendency as experimental results. It shows no defect along the fiber orientation from 0?? to 90??. However, in the range of fiber orientation from 90?? to 180??, it starts making defects inside UD CFRP workpiece because of fiber crush. It is verified by CT X-ray internal inspection. We need to consider poor machinability in the range of fiber orientation over 90??. In conclusion, this process will help optimize machinability in CFRP machining.ope

Finite element model of the drilling process of carbon fiber reinforced plastic (CFRP)

Department of Mechanical EngineeringCarbon fiber reinforced plastic (CFRP) is a composite, composed of reinforcing carbon fiber and matrix resin. CFRP is widely used in various fields, such as aerospace, automotive, robotics, and civil infrastructures, due to its excellent corrosion resistance and superior physical characteristics like strength-to-weight ratio, compared with traditional metals. Therefore, it has been constantly utilized and developed as the state-of-the-art material in numerous applications. Machining is indispensable when applying CFRP in these various industries, among which drilling process is indispensable for assembling different parts into products. However, unlike metals, CFRP holds heterogeneous properties. During the drilling process, delamination and uncut fibers are generated by the thrust force generated in the feed direction. While delamination at the outer surface can be detected by visual inspection, internal defect cannot be observed by the naked eye. These defects need to be predicted because of not only reducing the durability of the product but also causing deterioration in quality. This thesis presents the simplified FE model and method to predict the mechanical phenomena during the drilling process. To investigate these phenomena, a simulation model was developed with commercial FEM software, ABAQUS. Through the developed FE model, it was possible to predict the delamination through the stress distribution of each layer generated after the drilling process. In addition, it was possible to identify uncut fibers for each layer through this, and furthermore, the possibility of suggesting optimum processing conditions can be confirmed. Also, based on the analysis data obtained from the FE model, the change in the thrust force according to the drill entry position at the time of drilling was confirmed, and the accuracy of the developed analytical model was confirmed by comparing the experimental data with the analytical data. Therefore, FE model was developed to investigate defect prediction, and the results from FE analysis was compared this with experimental data to minimize errors in CFRP drilling process.ope

Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

Measuring and characterizing of surface roughness of machined surfaces of carbon fiber reinforced polymer (CFRP) composites are difficult due to the occurrence of special surface damages (delamination, uncut fibers, fiber pull-outs or micro-cracks, etc.). The main objective of the present study is to analyze the characteristics of surface roughness of machined unidirectional CFRP in detail. Numerous conventional drilling, helical milling, and edge trimming experiments were carried out with different cutting tools in order to analyze the influence of them on the average surface roughness (Ra), on the roughness depth (Rz) and on the Rz /Ra parameter. The surface roughness was measured by a Mitutoyo SJ-400 contact profilometer and an Alicona Infinite Focus confocal microscope. The usability of the contact profilometer was experimentally tested and compared its results with the results of the confocal microscope. Experimental results show that the contact profilometer is suitable for measuring surface roughness of CFRP, furthermore, values of Rz /Ra of drilled and edge trimmed surfaces of unidirectional CFRP are changing in a wide interval: from 5 to 14 μm/μm due to the special surface damages. Based on this research, the machinability analysis of CFRP is suggested to be extended to the analysis of the Rz /Ra parameter

Delamination prediction in orthogonal machining of carbon long fiber-reinforced polymer composites

Machining processes of composites are common operations in industry involving elevated risk of damage generation in the workpiece. Long fiber reinforced polymer composites used in high-responsibility applications require safety machining operations guaranteeing workpiece integrity. Modeling techniques would help in the improvement of machining processes definition; however, they are still poorly developed for composites. The aim of this paper is advancing in the prediction of damage mechanisms involved during cutting, including out-of-plane failure causing delamination. Only few works have focused on three-dimensional simulation of cutting; however, this approach is required for accurate reproduction of the complex geometries of tool and workpiece during cutting processes. On the other hand, cohesive interactions have proved its ability to simulate out-of-plane failure of composites under dynamic loads, as impact events. However, this interlaminar interaction has not been used up to date to model out-of-plane failure induced during chip removal. In this paper, both a classical damage model and cohesive interactions are implemented in a three-dimensional model based on finite elements, in order to analyze intralaminar and interlaminar damage generation in the simplified case of orthogonal cutting of carbon LFRP composite. More realistic damage predictions using cohesive interactions were observed. The strong influence of the stacking sequence on interlaminar damage has been demonstrated.Financial support for this work has been provided by the Ministry of Science and Innovation of Spain under the projects DPI2011-25999 and TRA2010-19573.Publicad

Quantification of drilling quality and mechanisms in CFRP composites

Drilling on fibre reinforced composites is a crucial process in fabrication of airframes in aircraft industry. In this research, an extensive experimental investigation on drilling and machining CFRP laminates using different tools is carried out to analyse effects of processing parameters on drilling performance. Drilling performance and quality of circular holes on a commercial aircraft CFRP laminate are investigated, using drill bit with three different configurations made of solid carbide, namely GT50 dagger drill, GT15 reamer drill, and twist drill. Back support of different geometry, as full support, partial support and no support, is employed during drilling at spindle speeds of 500, 1000, and 2000 rpm, and feed rate of 50 mm/min. Thrust force and torque, are measured. Quantification of the quality and holes integrity is accomplished by evaluating surface roughness, heat distribution, drilled hole roundness or circularity, chip size, and damage factor. The second major study is an energy-based analysis based on the energy balance model established by William’s on cutting polymers is presented by addressing Mode I fracture as a key mechanism in different cutting directions in a unidirectional CFRP laminate, induced by orthogonal cutting. Then, tool wear and tool life of dagger and reamer drill bits are investigated, evaluating blunting and wear of the tools. With that, assessment on tool wear and tool life are made by addressing their significant influence on thrust force and torque during drilling, delamination factor in the CFRP laminates, fibre peel-up and push-down mechanisms, surface roughness and temperature increase. Lastly, finite element analysis is added to explore and predict the drilling mechanism and chip removal mechanism as a function of failure criteria. With all that has been addressed above, this study plays a critical role for selection of the optimal drilling conditions for minimising production cost and maximising productivity

An energy based force prediction method for UD-CFRP orthogonal machining

The machining of carbon fiber reinforced polymer (CFRP) composite presents a significant challenge to the industry, and a better understanding of machining mechanism is the essential fundament to enhance the machining quality. In this study, a new energy based analytical method was developed to predict the cutting forces in orthogonal machining of unidirectional CFRP with fiber orientations ranging from 0° to 75°. The subsurface damage in cutting was also considered. Thus, the total specific energy for cutting has been estimated along with the energy consumed for forming new surfaces, friction, fracture in chip formation and subsurface debonding. Experiments were conducted to verify the validity of the proposed model

Drilling characteristics and properties analysis of fiber reinforced polymer composites: A comprehensive review

Fiber-reinforced polymer (FRP) composites play a vital role in the production of structural and semi-structural components for engineering applications. The drilling process is a commonly employed machining process for FRP composites to join the FRP structural elements. Usually, the FRP composites possess a heterogeneous nature because of their multi-layered structure, hybridization, and the presence of multi-phase materials. Hence, common problems like delaminations, fuzzing, buckling, cracking, matrix and fiber burning occur during the drilling operations. These problems cause dimensional inaccuracy, poor surface finish, and tool wear and reduce the mechanical strength of the composites. The optimum drilling parameters (drill geometry, speed, feed, and depth of cut) selection for the specific materials is good to achieve effective drilling performance and better surface quality of the holes. Yet, little study has been done on how all of these factors affect the size of the drilled hole. The majority of drilling studies on FRPCs in the past have focused on how to improve the hole quality by maximizing processing conditions, and there has been little discussion on the correlation between drilling conditions, physical properties, and production techniques. This is what motivated to review the characteristics and properties analysis of FRP composites. As a consequence of this research, it is anticipated that scientists and researchers would place a greater emphasis on the drilling characteristic of the workpieces made from FRPCs than on other attributes. This review clearly presents an overview of FRP composites drilling that had progressed from 2000 to 2021. The analysis of different drilling conditions and parameters like thrust force, drill geometry, temperature, speed, and feed also includes the post-drilling analysis through delaminations, thermal damage, and surface roughness. Furthermore, the recent developments in carbon, glass, and natural fiber reinforced polymer composites are studied with both conventional and nonconventional drilling techniques. Based on the above studies, some future challenges and conclusions are drawn from this review