Bearing strength performance: A study on the influence of <scp>AWJ</scp> drilling and delamination of <scp>GF</scp>/Al‐mesh reinforced polymer composites

Thermoplastic polycarbonate provides minimal structural weight and ductility and is a recyclable material. However, investigation of the characteristics of hybrid composites reinforced with woven glass and polycarbonate sheets is limited. This current study investigated the effect of integration of polycarbonate sheets on glass fiber‐epoxy hybrid composite performance. Non hybrid laminate was fabricated from eight layers of woven glass fiber impregnated with epoxy resin (NG). However, the hybrid samples utilized various symmetric stacking patterns which were made by alternating two processed polycarbonate (PC) sheets with six layers of woven glass fiber embedded with epoxy matrix. The manufacturing was made using the hand layup procedure. Mechanical testing includes compressive, tensile, bearing, and hardness was performed on hybrid and non‐hybrid composites. The results showed that employing PC sheets instead of fibers affect the laminate's strength, ductility, bearing capacity, and hardness. Utilization of PC sheets reduces both compressive and tensile strength. However, an enhancement in tensile, compressive, and bearing failure strain was achieved by 2.5%, 31.25% and 31.7%, respectively with hybrid composite having PC in the skin layers as compared with NG. The extent of failure damage is correlated with the position of the PC sheets in the tested samples.Highlights Novel hybrid composites of woven glass fiber and polycarbonate sheet as reinforcement with various stacking orders were successfully prepared by the hand lay‐up method. The compressive strain of hybrid PC samples are higher than NG sample. The hybrid PC composites showed an improved bearing strength and strain performance. The influence of sample configuration on the damage mechanisms has been investigated.

Studying the effect of polycarbonate sheet integration on glass fiber‐epoxy hybrid composite performance for automotive applications

Seif,

Awd Allah,

Megahed

et al. 2024

Geometry accuracy control in abrasive water jet taper hole machining of ultra‐thick carbon fiber‐reinforced polymer (CFRP) laminates

Liang,

Cheng,

Dong

et al. 2024

The primary factors affecting the geometric accuracy of abrasive water jet (AWJ) machining of ultra‐thick carbon fiber‐reinforced polymer (CFRP) laminates are the cutting front drag and kerf width deviation caused by energy dissipation. Firstly, this study comprehensively analyzes the influence of the coupling relationship between cutting front drag and kerf width deviation on the geometric accuracy of hole machining. Secondly, a gradient distribution theory for jet traverse speed with cutting depth is proposed for taper hole machining characteristics. Finally, a general geometric error model applicable to both straight and taper hole machining of ultra‐thick CFRP laminates using AWJ is established, along with a geometric error compensation method. A series of experiments validate the accuracy of the proposed geometric error model and compensation method. The novelty of this research lies in unifying the geometric error models for straight and taper hole machining of ultra‐thick CFRP laminates by considering the gradient distribution of jet traverse speed. The proposed error compensation method reduces the high degree of freedom required for machine tools. This study provides a general geometric error model and compensation strategy for AWJ hole machining of ultra‐thick CFRP laminates, which has significant engineering value for achieving 3D controllable AWJ machining of complex ultra‐thick CFRP components.Highlights The high geometric precision taper holes machining technique is a necessary prerequisite for achieving precise machining of complex trajectories in ultra‐thick CFRP with abrasive water jet. The influence of the coupling relationship between cutting front drag and kerf taper on the geometric accuracy of hole processing is comprehensively analyzed. A model considering the gradient distribution of traverse speed during taper holes machining was established, and a geometric error model considering this gradient distribution of traverse speed was developed. A taper holes machining geometric error compensation method with high engineering applicability was proposed. Geometric error prediction experiments and error compensation experiments were conducted, and the results proved the accuracy of the geometric error model and error compensation method.

Quality prediction and process optimization in abrasive waterjet cutting of ultra‐thick carbon fiber reinforced polymer

Liang,

Cheng,

Dong

et al. 2024

Surface roughness and delamination extent are key indicators for assessing the surface quality of machined carbon fiber reinforced polymer (CFRP) laminates. This study conducted an in‐depth investigation on the uncontrollable surface quality of abrasive water jet (AWJ) machining of ultra‐thick CFRP. Considering the sensitivity of the laminate structure to the jet impact angle, an optimized response surface methodology was used to analyze the effects of process parameters on surface roughness. Additionally, the differences in surface roughness on both sides of the kerf under non‐orthogonal cutting were examined. Based on these analyses, a surface roughness prediction model was developed. Furthermore, the study comprehensively analyzed the effects of material mechanical properties and process parameters on delamination damage. Using dimensional analysis, a predictive model for the maximum delamination length, considering jet energy dissipation, was established. The novelty of this research is to reveal the difference in surface quality on both sides of the kerf under non‐orthogonal cutting, and to establish prediction models for surface roughness and delamination damage based on the energy dissipation characteristics of ultra‐thick CFRP AWJ machining. This research provides essential modeling foundations for enhancing the controllability of AWJ machining quality for ultra‐thick CFRP complex components.Highlights Surface roughness and delamination damage impact AWJ use for ultra‐thick CFRP. Non‐orthogonal cutting causes surface quality differences on kerf sides. A model for kerf surface roughness at any jet impact angle was established. The delamination mechanism in internal path cutting was analyzed. The delamination length model for ultra‐thick CFRP laminates was established.