Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces

Henerichs, Marcel; Voß, Robert; Kuster, Friedrich; Wegener, Konrad

doi:10.1016/j.cirpj.2014.11.002

Cited by 108 publications

(50 citation statements)

References 18 publications

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“…In general, the influence of the cutting speed on the machining forces and the machining result is negligible compared to the machining of metal. Henerichs et al showed that feed force can be lowered with a high clearance angle and a small wedge angle [22]. A sharp tool with a small cutting edge radius reduces delamination [22].…”

Section: Methodsmentioning

confidence: 99%

“…A sharp tool with a small cutting edge radius reduces delamination [22]. Tsao and Hocheng showed that the feed force can be reduced with a pre-drilled hole [23].…”

Section: Ofmentioning

confidence: 99%

“…Henerichs et al showed that feed force can be lowered with a high clearance angle and a small wedge angle [22]. A sharp tool with a small cutting edge radius reduces delamination [22].…”

Section: Ofmentioning

confidence: 99%

See 2 more Smart Citations

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Sauer

Dix

Pütz

2018

JMMP

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Reliable machining of carbon fiber-reinforced plastics (CFRP) is the key for application of these lightweight materials. Due to its anisotropy, CFRP is a very difficult material to machine because of occurring delamination and fiber-pullouts. The tool design is especially crucial to minimize and to avoid these processing errors. In this paper a process analysis for drilling is shown for better understanding of the chip formation. Drilling of unidirectional CFRP enables the investigation of the effect of fiber orientation on the chip formation process. In theory, the amount of cut fibers and the cutting angle to the main cutting edge determine the cutting force. Experimental tests with varied macroscopic drill geometries verify this theory. Based on these detected relationships, the tool loads can be calculated for a successful tool design.

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Section: Methodsmentioning

confidence: 99%

“…A sharp tool with a small cutting edge radius reduces delamination [22]. Tsao and Hocheng showed that the feed force can be reduced with a pre-drilled hole [23].…”

Section: Ofmentioning

confidence: 99%

See 1 more Smart Citation

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Sauer

Dix

Pütz

2018

JMMP

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“…The orientation of the fibers in the stacking sequence of the laminate during the material removal process has attracted great attention. It has been studied in several works on orthogonal cutting, in which the cutting edge is perpendicular to the cutting movement direction [9][10][11][12]. This process is very useful, because it simplifies the working conditions.…”

Section: Introductionmentioning

confidence: 99%

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

et al. 2019

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Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

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“…Çalışmalarda farklı takımların ve takım geometrisinin delaminasyon ve kesme kuvvetlerine etkisinin araştırıldığı durumlara da rastlanmaktadır [8,9]. Ayrıca fiber oryantasyonunun karbon fiber takviyeli kompozitlerin işlenmesindeki etkilerinin araştırıldığı çalışmalarda literatürde mevcuttur [10][11][12][13].…”

Section: Gi̇ri̇ş (Introduction)unclassified

Karbon fiber takviyeli kompozit (KFTK) malzemelerin frezelenmesinde delaminasyon ve kesme kuvvetlerinin değerlendirilmesi ve matematiksel modellenmesi

Yağmur

Kurt

Şeker

2019

Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi

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Highlights:Graphical/Tabular Abstract  Milling of carbon fiber reinforced composites  Effects of different geometry tools on delamination  ANOVA statistics for delamination and cut3Nowadays, weight reducing is become possible with composite materials taking placeof steel (60-80) and aluminum (20-50%). Composite materials have become the preferred materials for many engineering applications. However, besides the advantages of composite materials, there are problems in manufacturing.Manufacturing of fiber-reinforced composite materials are more difficult than other materials. This situation needs to be very selective in terms of cutting tools. In this study, contour millind was realized of carbon fiber reinforced composite materials with PCD cutting tolls. Delamination and cutting forces have been studied investigated. After the experiments, it has been seen that increasing the cutting speed has a positive effect on the delamination, cutting forces and the best performance has shown the T1. According to ANOVA statistics, the most effective parameter in terms of delamination is cutting speed. According to ANOVA statistics, the most effective parameter in terms of cutting forces is second clearance angle. A schematic representation of the experimental setup is shown in Figure 1. Figure A. Schematic representation of the experimental setupPurpose: In this study, a unique PCD cutting tool design was devised which is capable of eliminating the encountered difficulties, especially the delamination problem on laminated/laminar formed composite board during machining carbon fiber reinforced composite (CFRC) materials. And cutting tools performance has been investigated in terms of delamination and cutting forces. Theory and Methods:Contour milling of KFTK materials was carried out with PCD cutting tools. The experiments were performed at the CNC vertical machining center. Three different cutting speed and constant feed rate used in experiments. Results:T1 tool has shown the best performance in terms of delamination and cutting forces between the designed and manufactured of the cutting tools. The best result in terms of delamination occurred at a cutting speed of 450 m / min with T1 tool. Cutting speed increase positively influenced delamination and cutting forces. According to model results the most important parameter affecting delamination is the cutting speed Conclusion:The performance of the designed and manufactured cutting tools are very good. The T1 coded cutting tool has the best performance among these cutting tool.

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Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces

Cited by 108 publications

References 18 publications

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

Karbon fiber takviyeli kompozit (KFTK) malzemelerin frezelenmesinde delaminasyon ve kesme kuvvetlerinin değerlendirilmesi ve matematiksel modellenmesi

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