Performance and mechanism of hole-making of CFRP/Ti-6Al-4V stacks using ultrasonic vibration helical milling process

Zou, Yuhe; Chen, Guang; Ren, Chengzu; Ge, Jiaying; Qin, Xuda

doi:10.1007/s00170-021-07906-6

Cited by 8 publications

(5 citation statements)

References 43 publications

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“…On the contrary, Be [17] is acknowledged for its inherent hardness and granular state, requiring powder metallurgy technology. Additionally, Be and its compounds are toxic, which can incur high costs and complexity in manufacturing and repair/service [18][19][20][21]. This inherent characteristic poses challenges in attaining polished and flawless surfaces due to the abrasive nature of the hard particles, thereby exacerbating tool wear during the machining of an injection moulding insert of a Cu-Be [22] alloy by amplifying the costs and intricacy associated with manufacturing and repair/service procedures [19].…”

Section: Copper-beryllium Alloys (Ampco ® )mentioning

confidence: 99%

“…Delamination damage is still a challenge when machining with coated tools. Four techniques were devised by Zou et al [18] during the helical milling of CFRP/Ti-6Al-4V stacks with coated tools. Based on experimental data, it was discovered that the extent of delamination damage is linked to the axial cutting load and can be curtailed by altering the sequence of the stacks [96].…”

Section: Millingmentioning

confidence: 99%

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A Concise Review on Materials for Injection Moulds and Their Conventional and Non-Conventional Machining Processes

Pedroso,

Sebbe,

Silva

et al. 2024

Machines

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Injection moulds are crucial to produce plastic and lightweight metal components. One primary associated challenge is that these may suffer from different types of failures, such as wear and/or cracking, due to the extreme temperatures (T), thermal cycles, and pressures involved in the production process. According to the intended geometry and respective needs, mould manufacturing can be performed with conventional or non-conventional processes. This work focuses on three foremost alloys: AMPCO® (CuBe alloy), INVAR-36® (Fe-Ni alloys, Fe-Ni36), and heat-treated (HT) steels. An insight into the manufacturing processes’ limitations of these kinds of materials will be made, and solutions for more effective machining will be presented by reviewing other published works from the last decade. The main objective is to provide a concise and comprehensive review of the most recent investigations of these alloys’ manufacturing processes and present the machinability challenges from other authors, discovering the prospects for future work and contributing to the endeavours of the injection mould industry. This review highlighted the imperative for more extensive research and development in targeted domains.

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Section: Copper-beryllium Alloys (Ampco ® )mentioning

confidence: 99%

Section: Millingmentioning

confidence: 99%

A Concise Review on Materials for Injection Moulds and Their Conventional and Non-Conventional Machining Processes

Pedroso,

Sebbe,

Silva

et al. 2024

Machines

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show abstract

“…There is scant information reported in the open literature, on the deployment of other non-conventional machining techniques such as ultrasonic vibration assisted machining (UVAM) and electrical discharge machining (EDM). According to the literature, UVAM can facilitate chip breaking, reduce cutting force, extend tool life extension and suppress delamination / burr in machining of CF/epoxy [128][129][130], metals [131,132] and their stacked structures [133][134][135]. On the other hand, EDM shows minimized geometric deviations and improved surface quality in machining of CF/epoxy [136,137].…”

Section: Laser Beam Machining (Lbm)mentioning

confidence: 99%

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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“…Several researchers have used different technologies to limit tool wear. For example, Zou et al [25] applied ultrasonic vibrations to hole-making in CFRP/Ti6Al4V through helical milling. The driving cause of immature failure was found to be abrasive and adhesive wear.…”

Section: Introductionmentioning

confidence: 99%

Using Nano-Fluids Minimum Quantity Lubrication (NF-MQL) to Improve Tool Wear Characteristics for Efficient Machining of CFRP/Ti6Al4V Aeronautical Structural Composite

Mughal

Farooq

et al. 2023

Processes

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The aeronautical industry constantly strives for efficient technologies to facilitate hole-making in CFRP/Ti6Al4V structural components. The prime challenge in this direction is excessive tool wear because of the different engineering properties of both materials. Nanofluid minimum quantity lubrication (NF-MQL) is the latest technology to provide synergistic improvement in tool tribological properties and lubrication function during machining. In the current study, an MoS2-based NF-MQL system was applied during helical milling using a FIREX-coated tool. In-depth analysis of wear, a scanning electron microscope (SEM), and electron deposition spectroscopy (EDS) were used to evaluate workpiece elemental transfer and tool wear mechanisms. Experimental findings showed that 1% nanoparticles concentration in lubricant resulted in low tool wear of 13 µm after 10 holes. The SEM and EDS analyses depicted formation of tribo-film on the surface, resulting less severe wear and a reduced degree of adhesion. However, a low nanoparticle concentration of 0.5% resulted in 106 µm tool wear after 10 holes with slight evidence of tribo-film. Parametric analysis based on eccentricity, spindle speeds (individual for CFRP and Ti6Al4V), axial pitch, and tangential feed showed correlations with mechanical damage. An extended study of up to 200 holes showed diffusion of C element at a high rate as compared to metal elements such as W and Co. The lowest tool wear was observed using eccentricity level 1, spindle speed Ti6Al4V 1000 rpm, spindle speed CFRP 7500 rpm, tangential feed 0.01 mm/tooth, axial pitch 1.5 mm, and 1% of MoS2 nanoparticles.

show abstract

Performance and mechanism of hole-making of CFRP/Ti-6Al-4V stacks using ultrasonic vibration helical milling process

Cited by 8 publications

References 43 publications

A Concise Review on Materials for Injection Moulds and Their Conventional and Non-Conventional Machining Processes

A Concise Review on Materials for Injection Moulds and Their Conventional and Non-Conventional Machining Processes

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

Using Nano-Fluids Minimum Quantity Lubrication (NF-MQL) to Improve Tool Wear Characteristics for Efficient Machining of CFRP/Ti6Al4V Aeronautical Structural Composite

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