Experimental investigation on micromachining of epoxy/graphene nano platelet nanocomposites

Abstract

This paper investigates the effect of graphene nano platelet (GNP) content (%weight fraction) on the machinability of epoxy/ GNP nanocomposites. The machinability of nanocomposites with varying loadings of GNP content was evaluated experimentally through the characterisation of cutting forces, surface morphology, chip morphology and tool wear. The minimum chip thickness phenomena of epoxy/GNP occurred at feed per tooth (FPT) between 0.2 and 0.4 μm. In order to achieve to better surface quality, the FPT should be over 0.4 μm. Epoxy/GNP with 1.0 wt% nanocomposite has produced the highest cutting force of a feed rate of~3 N at 12 μm/rev. Epoxy/GNP nanocomposites exhibit the different cracking tendencies compared with plain epoxy, and the tool wear for GNP/epoxy nanocomposites is very small compared with metal nanocomposites. There is no significant difference in slot width accuracy between different types of tools, such as uncoated tool, diamond-like carbon-coated and diamond-coated tools.

Finite element and experimental studies on the machining process of polymer/graphene nanoplatelet nanocomposites

“…These particles act as sharp cutting-edge, leading to increased residual stress or severe plastic deformation on the machined surface. This phenomenon has been widely acknowledged by researchers in both experimental and simulation work [43]. Generally, high contact stress at the tool-particle interface has been recognised as the main cause of tool wear.…”

FE-simulation of machining processes of epoxy with Mulliken Boyce model

“…The simulation results are significantly lower than those from the experiment. The simulation cutting force of epoxy is about 2.0 N/m, but the experimental value is approximately 4 N/m [63]. This may be due to three reasons [56].…”

A review on tool wear issues in drilling CFRP laminates

“…Therefore, measuring the average flank wear width can ensure a fair evaluation of tool performance and its serving life. Since such a measurement can be done manually via an optical microscope, it has become a convenient means being extensively used in various studies (Inoue et al, 1997;Ogawa et al, 2012Ogawa et al, , 2015James and Sonate, 2018;Dogrusadik and Kentli, 2019a;Dogrusadik and Kentli, 2019b;Kim et al, 2019;Fu et al, 2020;Huang et al, 2021;Kim et al, 2021). However, since the flank wear land around drill edges is often nonuniform and irregular, flank wear width may not be a perfect indicator to quantify the actual drill wear severity during drilling of CFRP laminates.…”