A review on research progress of machining technologies of carbon fiber-reinforced polymer and aramid fiber-reinforced polymer

Abstract

Since the application of fiber-reinforced polymer continues to expand, the demands of product quality for secondary cutting process are becoming increasingly higher to ensure the accurate coordination, connection, and assembly. There are some defects such as tearing, burr, delamination, and thermal damage after secondary cutting process, which limit the further applications of the materials. It is urgent to carry out comprehensive research on the secondary processing technology. In this paper, the fiber-reinforced composites' category, characteristics, and their applications were first described. Then the cutting performances, the causes of machining defects, and machining mechanisms have been analyzed. Finally, different compound processing methods, their characteristics, and applications have been elaborated. The most common forms of compound processing method including combined machining of cutting and grinding, ultrasonic vibration–assisted machining, and low-temperature–assisted machining have been covered in this paper. Results show that the compound processing method is the most effective way for improving the second processing quality of fiber-reinforced polymer. More machining mechanisms and applications of compound processing method need further experimental research. The barriers and future in the fields of research on machining of fiber-reinforced composites have been analyzed in this paper.

Machining quality of high speed helical milling of carbon fiber reinforced plastics

“…It dropped down slightly as the increasing of cutting speed until 10,000 r/min as found in previous studies. 22,24,30,47 It can be explained by the reduction in tool wear the decreasing of cavity volume as verified by Fuji et al 48 Then its variation was changed to slight elevation with cutting speed which is verified by some of studies 23,36,48 as well, and it can be explained by the warming and creating of heat affected zone in machined surface with high cutting speed that leads to the degradation of matrix and melting of fibers and affecting the surface roughness.…”

“…So the optimum surface roughness quality was obtained with the cutting tools with a low number of flutes and acute helix angle. 27,[29][30][31] Cherif et al 32 confirmed that the profile obtained for surface roughness measurement along the hole surface of a composite laminate depends significantly on the angular position of measurement. In order to characterize the roughness of the drilled hole in a composite laminate, it is essential to measure several profiles over a minimum angular extent of 90 .…”

A novel approach for removal of delaminated fibers of a reinforced composites using electrochemical discharge machining

“…The authors summarized that the quality of the hole can be enhanced by low feeds and high spindle speeds. Shi et al 10 reviewed the compound machining processes (ultrasonic-assisted mechanical machining and cutting-grinding compound machining) during drilling of CFRP and aramid fiber-reinforced polymer (AFRP). The authors found that burr (delaminated fibers) and tear defects are effectively controlled during the process.…”

CFRP composite drilling through electrical discharge machining using aluminum as fixture plate

“…Modern manufacturing demands strategies for machining fibrous composites because of their wide range of applications due to some peculiarities such as high strength at low weight, high creep, good wear and corrosion resistance, low density, low thermal expansion coefficient, and high dimensional stability. [1][2][3][4][5][6][7][8][9] Nowadays, the carbon fiber reinforced polymer (CFRP) is mostly adopted in aerospace industries for fabricating critical parts of modern aircraft, [1][2][3] fabrication of sporting items, 2 defence applications, 2,4 and chemical industries 4,5 because of its significant characteristics. Requirements of a smooth hole with low delamination, burr formation, taper, better circularity, and high processing speed set challenges for conventional machining processes.…”