Chatter stability and surface quality in milling of unidirectional carbon fiber reinforced polymer

Hou, Yao; Yao, Peng; Zhang, Heyong; Liu, Xiang; Liu, Hanlian; Huang, Chuanzhen; Zhang, Zihao

doi:10.1016/j.compstruct.2021.114131

Cited by 23 publications

(7 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The softened matrix causes the flexible fibers to escape from the cutting edge and diffuse to a larger area, especially in the 90° and 135° directions [61]. Ghidossi et al [62,63] also proved that tool wear was the main cause of burr in edge milling. Wang et al [57] used cohesive elements to simulate interlaminar fracture and inserted bonding elements along the fiber direction into the top layer of CFRP to simulate interlaminar cracks.…”

Section: Burrmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

View full text Add to dashboard Cite

Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

show abstract

Section: Burrmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

View full text Add to dashboard Cite

show abstract

“…Hence, CFRPs have strong However, owing to the nonuniformity and anisotropy of CFRPs, the application of conventional processing techniques can lead to poor material integrity as well as damage phenomena such as burrs and delamination (Geier et al, 2019). The milling process can cause burrs and delamination of uncut fiber yarns (Hou et al, 2021). Turning and drilling processes can lead to severe tool wear and poor surface integrity (Lin and Chen, 1996).…”

Section: Cutting Of Advanced Aerospace Materialsmentioning

confidence: 99%

Ultrasonic vibration cutting of advanced aerospace materials: a critical review of in-service functional performance

Peng,

Han,

Wang

et al. 2024

JIMSE

View full text Add to dashboard Cite

PurposeUnconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.Design/methodology/approachThe surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.FindingsTo address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.Originality/valueThis study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

show abstract

“…Numerical modeling validation on experiments with composites of short filler have been reported in recent times. The use of random sequential adsorption algorithm (RSA) technique helps in creating representative volume element (RVE) with short fillers randomly oriented and distributed at low to a very high volume fraction (up to 80%) 31–35 . The spatial arrangement was typically assumed to be regular and periodic for simplicity in the early analysis of composite materials.…”

Section: Introductionmentioning

confidence: 99%

“…The use of random sequential adsorption algorithm (RSA) technique helps in creating representative volume element (RVE) with short fillers randomly oriented and distributed at low to a very high volume fraction (up to 80%). [31][32][33][34][35] The spatial arrangement was typically assumed to be regular and periodic for simplicity in the early analysis of composite materials. Such models, though, have a lot of drawbacks due to their regular spatial arrangement.…”

Section: Introductionmentioning

confidence: 99%

Effect of glass fiber reinforcement on compressive strength of photopolymer composite fabricated using vat‐photopolymerization additive technique: An experimental and modeling approach

Moharana,

Kumar,

Raj

et al. 2023

Polymer Composites

View full text Add to dashboard Cite

Short or nanofillers‐reinforced composites increase the thermo‐mechanical characteristics of additive manufacturing (AM) base materials. Effective outputs were regulated via parametric optimisation and custom production. One of the most used AM method, Vat photopolymerization (VPP), creates complex and geometrically precise photopolymer parts. This study prepares photopolymer composite (PPC) samples with 2.0, 4.0, 6.0, and 8.0 volume percentages of short glass fiber (SGF) using an inter‐stage stirring method in DLP‐based VPP process. An adequate curing time and formable layer thickness were evaluated for the printability performance of SGF‐photopolymer composite. The 4.0% PPC‐sample showed a 20% higher compressive yield strength than pure photopolymer and other volume fractions. The consequences of increased strength values were assessed by the effect of stirring method and the fractography analysis of PPC specimen. The investigation additionally encompassed numerical simulations that employed an innovative technique for constructing and simulating three‐dimensional representative volume elements (RVEs). The RVEs were designed to replicate the experimental outcomes by randomly situating and orienting fillers within the matrix. The study employs the calibrated Three Network (TN) viscoplastic constitutive material model as the matrix property, and the simulation results demonstrate a margin of error of 5%–10% when compared to the experimental findings.Highlights Layer‐wise availability of SGFs through inter‐stage stirring method The exposure time and layer thickness were determined by Jacob's working curve Concept of RVE is used to combine individual SGF layers into a single layer SEM showed that increasing SGF layer resists cracking better than neat matrix Experimental data and numerical simulations are in good agreement

show abstract

Chatter stability and surface quality in milling of unidirectional carbon fiber reinforced polymer

Cited by 23 publications

References 28 publications

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Ultrasonic vibration cutting of advanced aerospace materials: a critical review of in-service functional performance

Effect of glass fiber reinforcement on compressive strength of photopolymer composite fabricated using vat‐photopolymerization additive technique: An experimental and modeling approach

Contact Info

Product

Resources

About