Numerical and experimental investigation of orthogonal cutting of carbon fiber-reinforced polyetheretherketone (CF/PEEK)

Qin, Xuda; Wu, Xiaozhong; Li, Hao; Li, Shipeng; Zhang, Shiguang; Jin, Yan

doi:10.1007/s00170-021-08317-3

Cited by 26 publications

(13 citation statements)

References 38 publications

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“…As shown by Fig. in drilling of thermoplastic CF/PEEK [28], CF/pCBT [42] and CF/ABS [30,43], milling of CF/polyurethane [44] and orthogonal cutting of CF/PEEK [45]. Compared to CF/PEKK, the CF/epoxy chips are less intact and contain micro-cracks.…”

Section: Chip Formationmentioning

confidence: 99%

Temperature field evolution and thermal-mechanical interaction induced damage in drilling of thermoplastic CF/PEKK – A comparative study with thermoset CF/epoxy

Luo

Zhang

et al. 2022

Preprint

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Although new generation carbon fibre reinforced thermoplastic (CFRTP) such as carbon fibre reinforced polyetherketoneketone (CF/PEKK) is a promising sustainable alternative to the conventional thermoset CFRP, there is a lack of literature regarding its machining performance. This is the first study unveiling the hole wall and chip temperature evolution during drilling of thermoplastic CF/PEKK composite and the resulting material damages have been studied in detail. Through comparative study with CF/epoxy, the disparate drilling performance of the two composites has been uncovered, and the results were found to be closely related to the materials’ thermal/mechanical properties. Specifically, CF/PEKK produces continuous chips due to its excellent ductility and thermal sensitivity, whereas CF/epoxy produces segmented chips due to its brittle nature. CF/PEKK generates up to 40 N (50.5%) higher thrust force, 87.6 ℃ (98.9%) higher hole wall temperature and 61.1 ℃ (48.8 %) higher chip temperature than that of CF/epoxy. This has been correlated to the longer tool-chip contact length of CF/PEKK and its unique chip morphology. Despite the greater thrust force/temperature generation, CF/PEKK shows 55.7% lower delamination damage than CF/epoxy, and this is owning to its excellent interlaminar toughness. This study establishes a more in-depth understanding into the drilling performance of thermoplastic CF/PEKK and thermoset CF/epoxy and also provides guidance on the high performance manufacturing of next generation CFRPs.

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Section: Chip Formationmentioning

confidence: 99%

Temperature field evolution and thermal-mechanical interaction induced damage in drilling of thermoplastic CF/PEKK – A comparative study with thermoset CF/epoxy

Luo

Zhang

et al. 2022

Preprint

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“…5 (c). For the same composite, Qin et al [50] developed a microscale model to simulate the microstructural fibre fracture behaviours at four typical fibre cutting orientations. To further validate their model, Qin et al [50] also carried out microscopic investigation.…”

Section: Chip Formationmentioning

confidence: 99%

“…For the same composite, Qin et al [50] developed a microscale model to simulate the microstructural fibre fracture behaviours at four typical fibre cutting orientations. To further validate their model, Qin et al [50] also carried out microscopic investigation. Long continuous curly chips were found for 0° < 𝜃𝜃 < 45°, whereas short chunky chips were found at 𝜃𝜃 = 90° and 135°, see Fig.…”

Section: Chip Formationmentioning

confidence: 99%

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Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Luo

Catalanotti

et al. 2023

Preprint

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Fibre reinforced thermoplastic polymer (FRTP) composites have been used for a wide range of engineering applications (e.g. in transport, construction, energy, etc) due to their excellent mechanical properties and ease of repair and recycling. In recent years, FRTP is increasingly deployed as an alternative to conventional thermoset carbon fibre reinforced epoxy (CF/epoxy) composites, for the purpose of reducing the carbon footprint and contributing to a sustainable manufacturing agenda. Machining of FRTP remains an indispensable process to achieve rapid parts assembly whilst meeting stringent geometric tolerances. However, due to the heterogeneous structure and high thermal sensitivity of FRTP, a range of machining-induced damages (such as matrix smearing, thermal degradation, delamination, burr and surface cavity) often occur, leading to concerns on machined parts quality and reliability. To date, composite machining studies have been mostly focused on conventional thermoset CF/epoxy and there is a lack of an up-to-date, in-depth review of the latest advancement concerning the machining of FRTP. This paper provides a state-of-the-art overview on the recent developments in FRTP machining over the past decade, with a particular emphasis on machining characteristics, damage mechanisms as well as the challenges facing such manufacturing process. The purpose is to present the composite manufacturing community with a timely update, which may guide and inspire further research and development for future FRTP manufacturing.

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“…Frequently used feedstocks such as acrylonitrile–butadiene–styrene (ABS) and polylactide (PLA) have been extensively studied. In recent years, carbon fiber–reinforced poly-ether-ether-ketone (CFR-PEEK) has emerged as another option, as parts printed using CFR-PEEK exhibit superior mechanical properties when compared to ABS and PLA [ 24 , 25 ]. Despite the advantages of CFR-PEEK, parts printed using it require additional time to finish printing [ 26 ] and thereby increase EC.…”

Section: Introductionmentioning

confidence: 99%

Simulating energy consumption based on material addition rates for material extrusion of CFR-PEEK: a trade-off between energy costs and cycle time

Hassan

Noh

Park

et al. 2022

Int J Adv Manuf Technol

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While many studies for material extrusion–based additive manufacturing (AM) of polymers focus on experimental approaches to evaluate relevant performance measures from process parameters, there is a lack of discussion to connect experimental results with useful applications. Also, one of the major deficiencies in the application literature is a trade-off analysis between energy costs and cycle time (time to produce an item from the beginning to the end) since improving these two measures simultaneously is challenging. Thus, this paper proposes an energy simulation method for performing a trade-off analysis between energy costs and cycle time using combinations of major AM process parameters for material extrusion. We conduct experiments using carbon fiber–reinforced poly-ether-ether-ketone (CFR-PEEK), which is increasingly used in material extrusion. From experimental results, we build a power model in which power (kW) is derived as a linear function of material addition rates (MAR). This MAR regression model is then used in a proposed simulation model that integrates discrete event simulation and numerical simulation. In our simulation case study of 50 machines and 40 scenarios, we investigate trade-offs between energy costs and cycle time with three control policies (P 1 , P 25 , and P 50 ) that allow 1, 25, or 50 machines to start heating, respectively. The trade-off analysis results show that P 25 can be preferred when a balance between cycle time and energy costs is pursued, while P 1 or P 50 can be chosen if either energy cost (with P 1 ) or cycle time (with P 50 ) is more important than the other measure. Moreover, we find that the machine utilization, variability, and product volume have significant effects on energy costs and cycle time.

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Numerical and experimental investigation of orthogonal cutting of carbon fiber-reinforced polyetheretherketone (CF/PEEK)

Cited by 26 publications

References 38 publications

Temperature field evolution and thermal-mechanical interaction induced damage in drilling of thermoplastic CF/PEKK – A comparative study with thermoset CF/epoxy

Temperature field evolution and thermal-mechanical interaction induced damage in drilling of thermoplastic CF/PEKK – A comparative study with thermoset CF/epoxy

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Simulating energy consumption based on material addition rates for material extrusion of CFR-PEEK: a trade-off between energy costs and cycle time

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