Machining damage in FRPs: Laser versus conventional drilling

Hejjaji, Akshay; Singh, Dilpreet; Kubher, Sagar; Kalyanasundaram, Dinesh; Gururaja, Suhasini

doi:10.1016/j.compositesa.2015.11.036

Cited by 93 publications

(38 citation statements)

References 28 publications

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“…This makes machining of composites a complex problem because the mechanisms of material removal are strongly derived by relative angle between the direction of the cutting speed and the fibers direction [1,3]. Research conducted on conventional milling of FRPs shows many kinds of damages like delamination, fiber pull-outs, matrix recession, interlaminar cracks and thermal degradation whose nature, size and position chiefly depend on machining parameters and fiber orientation with respect to cutting direction [1][2][3][6][7][8][9]. Also conventional milling leads excessive and premature tool wear because of abrasive nature of the carbon fibers and also dangerous levels of dust is generated which affects the environment and is also harmful to the operator [6].…”

Section: Introductionmentioning

confidence: 99%

“…However, several studies report numerous defects delamination, matrix cracking, matrix degradation and burnout matrix recession, thermal damage in laser machining [7]. Also, other damages like high thermal degradation, recast layer and delamination along the spark channel can be observed in electrical discharge machining and defects like delamination, grit embedment and striations in AWJ machining [1,10,11].…”

Section: Introductionmentioning

confidence: 99%

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Surface and machining induced damage characterization of abrasive water jet milled carbon/epoxy composite specimens and their impact on tensile behavior

Hejjaji

Zitoune

Crouzeix

et al. 2017

Wear

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Francis Collombet. Surface and machining induced damage characterization of abrasive water jet milled carbon/epoxy composite specimens and their impact on tensile behavior. Wear, Elsevier, 2017, 376-377 (Part B), p. a b s t r a c t Controlled depth milling of composites structures by abrasive water jet (AWJ) is a new area of machining being explored and knowledge on this is bare minimum. Hence it is essential to investigate surface quality and damage induced to ascertain their mechanical reliability. Here, the mechanism of material removal is manifested by erosive wear. In this study, carbon fiber reinforced plastic (CFRP) laminates are milled using AWJ process and surfaces generated by varying process parameters are characterized using roughness systems, X-ray tomography and scanning electron microscopy (SEM). SEM images reveal presence of damages in form of craters, ridges, broken fibers and embedded abrasive particles. Crater formation due to erosion phenomenon is affected by jet pressure. It is seen that the crater volume increases by around 500% when pressure varies from 80 MPa to 140 MPa. In the literature reviewed correlation between roughness of the machined surface and the mechanical behavior is ambiguous and remains an open problem. Hence, novel attempt has been made to analyze the influence of damage (crater volume) on tensile strength. Mechanical tests on specimens with varying surface texture and crater sizes reveals that tensile strength of machined specimens is more influenced by crater volume rather than surface roughness.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Surface and machining induced damage characterization of abrasive water jet milled carbon/epoxy composite specimens and their impact on tensile behavior

Hejjaji

Zitoune

Crouzeix

et al. 2017

Wear

Self Cite

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“…High cutting temperature would cause machining defects, such as burn, delamination, pilling, and tearing. 13–16 Therefore, it is important to get cutting temperature during the machining practices. 17,18…”

Section: Introductionmentioning

confidence: 99%

Thermal characteristics of unidirectional carbon fiber reinforced polymer laminates during orthogonal cutting

Chen

Cai³

et al. 2018

Journal of Reinforced Plastics and Composites

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Carbon fiber reinforced polymer has been used as a major material for primary load-bearing structural components in aviation industry. But its poor heat resistance is an important factor affecting the machining performance, because high cutting temperature above glass transition temperature of resin matrix (normally 300°C or below) may lead to the degradation of the resin matrix. In this study, orthogonal machining experiments were conducted to investigate the effects of cutting parameters, cutting tool geometric parameters, and material parameters on cutting temperature, and the prediction model of cutting temperature about fiber orientation angle ( θ) was built. Cutting temperature was measured by semiartificial thermocouple method. The experimental results revealed that the influence of cutting parameters on cutting temperature was not affected by fiber orientation angle of carbon fiber reinforced polymer. Cutting tool geometric parameters have little effect on cutting temperature. Unlike metal materials, cutting temperature was greatly influenced by θ. Cutting temperature for θ < 90° was significantly higher than that for θ > 90°. The maximum temperature occurred at θ = 90°. The influence of fiber orientation angle was shown in two aspects: changing the springback of unidirectional-carbon fiber reinforced polymer laminates in cutting process, changing material removal mechanism, which affected cutting temperature eventually.

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“…Due to the inherent heterogeneity and anisotropy, conventional machining of polymer composites results in several kinds of damage. They are, in example, matrix cracking, fibers pullout, spalling, delamination, tool wear, thermal degradation, excessive dust generation, and so on . Due to these drawbacks, non‐conventional machining techniques, as abrasive water jet (AWJ) and laser beam machining, were adopted in last years.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, many authors have studied laser processing of composites materials. In their work , Hejjaji et al compared the characteristics of damage that resulted on glass and carbon composites from a laser and traditional drilling processes. Takahashi et al in Ref.…”

Section: Introductionmentioning

confidence: 99%

Multi‐response optimization of CFRP laser milling process based on response surface methodology

Genna

Tagliaferri

Papa

et al. 2017

Polymer Engineering & Sci

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In this study, ANalysis Of VAriance (ANOVA) and Response Surface Methodology were applied to characterize and optimize laser milling of Carbon Fiber Reinforced Polymer (CFRP) plates. The process was performed by means of a 30W Q-switched Yb:YAG fiber laser, working at the fundamental wavelength of 1064 nm. The machined material was a CFRP plate, 4 mm in thickness, obtained by autoclave cure. According to Design of Experiments (DoE) methodology and previous experiences, a Central Composite Design (CCD) was developed and applied. The investigated parameters were the scan speed, the pulse frequency, the number of repetitions of the geometric pattern and the hatch distance. The suitable milling conditions were obtained from the response surface model. The model allows to set the process parameters to obtain the desired depth with an error <3% and a MRR higher than 1.9 × 10−3g/s. POLYM. ENG. SCI., 57:595–605, 2017

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Machining damage in FRPs: Laser versus conventional drilling

Cited by 93 publications

References 28 publications

Surface and machining induced damage characterization of abrasive water jet milled carbon/epoxy composite specimens and their impact on tensile behavior

Surface and machining induced damage characterization of abrasive water jet milled carbon/epoxy composite specimens and their impact on tensile behavior

Thermal characteristics of unidirectional carbon fiber reinforced polymer laminates during orthogonal cutting

Multi‐response optimization of CFRP laser milling process based on response surface methodology

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