Machining damage and surface integrity evaluation during milling of UD-CFRP laminates: Dry vs. cryogenic

Kumar, Dhiraj; Gururaja, Suhasini

doi:10.1016/j.compstruct.2020.112504

Cited by 63 publications

(18 citation statements)

References 51 publications

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“…The resulting reduction of temperature in the cutting zone can explain this behavior since it would reduce the thermal degradation of the polymer matrix. This result is in good agreement with the observations of Kumar et al [59] who found that low temperatures tend to maintain or increase the properties of the CFRP (tensile strength, shear modulus and stiffness) which, in consequence, would produce greater resistance to delamination.…”

Section: Delaminationsupporting

confidence: 93%

“…For the 45 • fiber orientation, the fibers undergo both pulling and shearing [57]. It appears in Figure 6 that the resultant force increases proportionally to the feed rate, as usually expected when machining metals, polymers and composites since the chip thickness and cross section, and therefore the metal removal rates, are increased at a high feed rate [59]. The results presented in Figures 6 and 7 demonstrate that the machining of CFRP is improved with the use of the atomization-based vegetable oil spray as the lubricant.…”

Section: Cutting Forcesmentioning

confidence: 51%

“…When milling at 45 • , the abrasive action of the broken fibers is high. These fibers are broken because of the compression-induced shear perpendicular to the fiber direction [59]. When machining at 0 • , fiber delamination occurs because of micro-buckling and only limited fibers can fracture [67].…”

Section: Delaminationmentioning

confidence: 99%

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Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

et al. 2021

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Carbon fiber reinforced polymers (CFRPs) have found diverse applications in the automotive, space engineering, sporting goods, medical and military sectors. CFRP parts require limited machining such as detouring, milling and drilling to produce the shapes used, or for assembly purposes. Problems encountered while machining CFRP include poor tool performance, dust emission, poor part edge quality and delamination. The use of oil-based metalworking fluid could help improve the machining performance for this composite, but the resulting humidity would deteriorate the structural integrity of the parts. In this work the performance of an oil-in-water emulsion, obtained using ultrasonic atomization but no surfactant, is examined during the milling of CFRP in terms of fiber orientation and milling feed rate. The performance of wet milling is compared with that of a dry milling process. The tool displacement-fiber orientation angles (TFOA) tested are 0°, 30°, 45°, 60°, and 90°. The output responses analyzed were cutting force, delamination, and tool wear. Using atomized vegetable oil helps in significantly reducing the cutting force, tool wear, and fiber delamination as compared to the dry milling condition. The machining performance was also strongly influenced by fiber orientation. The interactions between the fiber orientation, the machining parameters and the tested vegetable oil-based fluid could help in selecting appropriate cutting parameters and thus improve the machined part quality and productivity.

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Section: Delaminationsupporting

confidence: 93%

Section: Cutting Forcesmentioning

confidence: 51%

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Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

et al. 2021

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“…Recently, the use of cryogenic cooling for machining of composites gains increasing interest. Significant decrease in surface damage and roughness and cutting temperature when cryogenic milling of unidirectional carbon fiber reinforced plastics (UD-CFRP) laminates was observed despite an increase in resultant forces for all fiber orientations [22].…”

Section: High Performance Cooling Techniques 21 Cryogenic Machiningmentioning

confidence: 99%

Review of new developments in machining of aerospace materials

Jemielniak¹

2021

Journal of Machine Engineering

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The paper presents an update of the recent literature on advances in machining of difficult to machine materials such as nickel and titanium-based alloys, and composites used in aeroengine and aerostructure applications. The review covers the following issues: advances in high-performance cooling techniques as cryogenic machining, minimum quantity lubrication, the combination of MQL and cryogenic cooling, and high-pressure lubricoolant supply and hybrid cutting processesvibration assisted machining (both low and high frequency), laser, plasma and EDM assisted machining. Examples of applications in industrial processes are also given.

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“…The influence of fiber orientation on cutting temperature measured using IR camera during milling of UD-CFRP laminate was shown in Ref. 31 A significant improvements in terms of reduced damage factor, machined surface roughness and cutting zone temperature during milling under cryogenic conditions for various UD-CFRP fiber orientations were observed. However, only the surface temperature behind the machining zone could be measured using the IR camera.…”

Section: Introductionmentioning

confidence: 98%

In-situ cutting temperature and machining force measurements during conventional drilling of carbon fiber polymer composite laminates

Kubher

Gururaja

Zitoune

2021

Journal of Composite Materials

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The evolution of in-situ cutting temperature and machining forces during conventional drilling of multi-directional carbon fiber reinforced polymer (MD-CFRP) laminates using a novel inverted drilling setup is presented. The in-situ cutting temperature was measured using fiber Bragg grating (FBG) optical sensor embedded in the stationary drill. The effect of machining parameters such as spindle speed and feed rate on the temperatures and machining forces were studied that indicate the predominant effect of spindle speed on machining temperatures. The drilled MD-CFRP samples and drill bits were characterized by scanning electron microscopy (SEM) and micro-computed tomography ([Formula: see text]) techniques to assess machining-induced damage in the samples and tool wear in the drill bits. Exit-ply delamination was observed in MD-CFRP samples that aggravates with increase in cutting temperature and thrust force caused by evolving tool wear. The measured in-situ machining temperatures using the current experimental setup can be used to achieve better machining models.

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Machining damage and surface integrity evaluation during milling of UD-CFRP laminates: Dry vs. cryogenic

Cited by 63 publications

References 51 publications

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

Review of new developments in machining of aerospace materials

In-situ cutting temperature and machining force measurements during conventional drilling of carbon fiber polymer composite laminates

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