Factors Affecting Workpiece Surface Integrity in Slotting of CFRP

El-Hofy, Mohamed; Soo, Sein Leung; Aspinwall, D.K.; Sim, W.M.; Pearson, D.; Harden, P.

doi:10.1016/j.proeng.2011.11.085

Cited by 87 publications

(32 citation statements)

References 5 publications

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“…10(b). These observations in CG were consistent with the work conducted by El-Hofy MH [25] when routing CFRP materials using polycrystalline diamond (PCD) end mills and Sein Leung Soo [4] when edge routing multi-directional CFRP panels with cylindrical steel cores with CBN grits and diamond grits on the surface.…”

Section: Comparison On Surface Integritysupporting

confidence: 86%

Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

Geng

Zhang

et al. 2015

Ultrasonics

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Section: Comparison On Surface Integritysupporting

confidence: 86%

Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

Geng

Zhang

et al. 2015

Ultrasonics

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“…They suggested that tool wear not just because of high cutting force and the abrasive nature of the reinforcement causes high tool wear rate. El-Hofy et al 13 also found that the fiber orientation, feed rate, and cutting speed have significant effects on machined surface roughness and integrity. According to their results, while high cutting speeds and low feed rates are recommended for CFRP edge trimming, a combination of low cutting speeds and high feed rates was recommended for reducing surface roughness during CFRP slot milling, with the feed rate being a significant factor.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of the cutting temperature and surface quality during milling of unidirectional carbon fiber reinforced plastic

Ghafarizadeh

Lebrun

Châtelain

2015

Journal of Composite Materials

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The surface machining of carbon fiber reinforced plastics materials is a challenging process, given the heterogeneity and anisotropic nature of composites, which, combined with the abrasiveness of the fibers, can produce some surface damage and extensive tool wear. The cutting temperature is one of the most important factors associated with the tool wear rate and machinability of these materials, which are also affected by the mechanical and thermal properties of the workpiece material and the cutting conditions. In this work, the cutting temperature, cutting forces, and composite surface roughness were measured under different cutting conditions for the end milling of unidirectional carbon fiber reinforced plastics. Cutting speeds ranging from 200 to 350 m/min; a feed rate of 0.063 mm/rev; fiber orientations of 0, 45, 90, and 135 ; and a 0.5 mm depth of cut were considered. The results show that the cutting speed and fiber orientation have a significant influence on the cutting temperature and cutting forces. The maximum and minimum cutting forces and temperatures were achieved for fiber orientations of 90 and 0 , respectively.

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“…For instance, the control of such defects as cutting delamination, tearing and burr etc. [3], and the improvement of tool durability, have become key limitations in the application of high-quality machining technology of CFRP materials.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Milling CFRP with Staggered PCD Cutter

et al. 2017

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Carbon fiber reinforced plastics (CFRP) have good physical properties, such as high specific strength and high specific modulus. However, cutting delamination, tearing and burr, etc. often occur in the machining process of CFRP, which results in the uncontrollability of machining surface quality and serious tool wear. In this paper, milling of CFRP with a staggered cutter was carried out, the cutting-edge radius was investigated in order to characterize the tool wear; the effect of the cutting-edge wear radius on the milling force and surface quality was found, and the formation mechanisms of the 3D surface topography and surface defects were analyzed under the wear state. Experimental results showed that the wear of the staggered PCD cutter was mainly concentrated in the cutting-edge area. With the increase in milling length, the radius of cutting edge gradually became largeer under the action of abrasive wear mechanism, and the flank wear was not obvious. With the intension of tool wear, milling force gradually increased and the machining surface quality of the CFRP deteriorated distinctly, i.e., defects such as bare fiber fracture, groove and hole appeared, and burrs were gradually generated on the workpiece surface. Finally, through a comparative analysis of cutting performance, it was found that the staggered PCD cutter possessed better performance for wear resistance and burr suppression than the straight-teeth cutter. This finding can provide theoretical and technical support for improving the machining quality of carbon fiber composite materials.

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Factors Affecting Workpiece Surface Integrity in Slotting of CFRP

Cited by 87 publications

References 5 publications

Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

Experimental investigation of the cutting temperature and surface quality during milling of unidirectional carbon fiber reinforced plastic

Experimental Study on Milling CFRP with Staggered PCD Cutter

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