Cutting Forces in Milling of Carbon Fibre Reinforced Plastics

Sorrentino, Luca; Turchetta, Sandro

doi:10.1155/2014/439634

Cited by 20 publications

(11 citation statements)

References 18 publications

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“…Examining the results of cutting forces, it can be noted that for both types of tools for f z = 0.04 mm/min and for the non-coated tool at f z = 0.12 mm/min, the cutting forces increased with an increase in the cutting speed. These results are consistent with some studies [ 35 , 36 ]. The cutting forces obtained after milling with the TiAlN-coated tool for f z = 0.12 mm/tooth decreased with an increase in the cutting speed.…”

Section: Discussionsupporting

confidence: 94%

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

et al. 2020

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In this study, the effect of cutting parameters on the quality of an Al/CFRP sandwich structure (aluminium alloy–carbon fibre reinforced polymer) after milling with uncoated and TiAlN-coated tools was examined. The results of the cutting force were also investigated. The research was conducted in a VMC 800 HS vertical machining centre with a variable cutting speed and feed. The milling process was carried out using a non-coated, two-blade carbide milling cutter with a 35° helix angle and an analogous tool with a TiAlN coating. The surface quality was characterised in terms of the height deviation, which is one of the shape deviations after machining hybrid materials. The research showed that the maximum (77.60 µm) and minimum (1.78 µm) values of the height deviations were obtained using the tool with a TiAlN coating. It was found that the tested factors had significant effects on the height deviation, where the feed had the greatest influence and the cutting speed had the lowest influence on the surface quality. The tested factors were not statistically significant in terms of the cutting force.

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Section: Discussionsupporting

confidence: 94%

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

et al. 2020

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“…Some experimental works of various manufacturing process (e.g., milling, drilling, trimming, etc.) have been done to investigate the cutting force [12,13], while numerical simulation works were performed to analyze the cutting force by using the micromechanical and macroscopic finite element method [14][15][16]. Furthermore, some analytical models were also proposed to predict the cutting force in FRP composites [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation

Gao

Xiao

et al. 2015

Int J Adv Manuf Technol

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A three-dimensional (3D) micromechanical finite element (FE) model of machining of fiber-reinforced polymer (FRP) composites was developed in the paper. The FE modeling considers the three phases of a composite, in which the interphase between the fiber and matrix can realize interfacial debonding to represent the failure of composites and allow heat transfer. The machined surface observations and surface roughness measurements of carbon fiber-reinforced polymer (CFRP) composites at different fiber orientations were done firstly, and then, the model predictions of the machining responses, such as cutting force, temperature, and surface roughness, at different fiber orientations were compared with various experimental data for model validation. It is indicated that the three-phase micromechanical model is capable of precisely predicting machining responses and describing the failure modes of fiber shearing or bending related with fiber orientations in the chip formation process. To investigate the complex coupling influences of multiple machining parameters on the key responses of CFRP composites, the singlefactor analyses of each machining parameter were first carried out, and then, the multi-factorial analysis of multiple machining parameters was performed based on the orthogonal design of experiment and the analysis of variance (ANOVA) to quantitatively compare the influences of these key machining parameters on the cutting force and surface roughness. It was found that the fiber orientation angle, depth of cut, and cutting speed prove to be the important factors affecting the cutting force and surface roughness and that the coupling effects of these machining parameters all are relatively negligible in the machining of CFRP composites.

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“…For every experiment two parallel notches are milled in opposite directions like it is shown in Figure 12. This leads to normal forces that point towards each other [20]. Consequentially a non-external controlled robot will be pushed away, which reduces the space between the notches.…”

Section: Milling Testsmentioning

confidence: 99%

Real Time Pose Control of an Industrial Robotic System for Machining of Large Scale Components in Aerospace Industry Using Laser Tracker System

Moeller

Schmidt

Koch

et al. 2017

SAE Int. J. Aerosp.

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The high demand of efficient large scale machining operations by concurrently decreasing operating time and costs has led to an increasing usage of industrial robots in contrast to large scaled machining centers. The main disadvantage of industrial robots used for machining processes is their poor absolute accuracy, caused by the serial construction, resilience of gearings and sensitivity for temperature changes. Additionally high process forces that occur during machining of CFRP structures in aerospace industry lead to significant path errors due to low structural stiffness of the robot kinematic. These errors cannot be detected by means of motor encoders. That is why calibration processes and internal control laws have no effect on errors caused by elastic deformation. In this research paper an approach for increasing the absolute accuracy of an industrial milling robot with help of a Laser Tracker system during machining tasks will be presented. To measure the position and orientation of the robot tool center point (TCP) a specific adapter is mounted on the milling spindle near the TCP to provide a 6DoF measurement. Via a real time interface pose data can be obtained in millisecond cycles and is used for calculating the current path errors of the robot. The implementation of an additional controller in the manufacturers CNC allows the correction of the programmed trajectory so that the machining path will match its specifications.

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Cutting Forces in Milling of Carbon Fibre Reinforced Plastics

Cited by 20 publications

References 18 publications

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation

Real Time Pose Control of an Industrial Robotic System for Machining of Large Scale Components in Aerospace Industry Using Laser Tracker System

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