Surface grinding of carbon fiber reinforced plastic (CFRP) with an internal coolant supplied through grinding wheel

Sasahara, Hiroyuki; Kikuma, T.; Koyasu, Rei; Yao, Yasuhiro

doi:10.1016/j.precisioneng.2014.04.005

Cited by 75 publications

(39 citation statements)

References 12 publications

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“…The CFRP composites were not sharply cut, resulting in the increase in surface roughness. 9,36 In addition, the tool with abrasive concentration of 75 had more cavities between the tool and the workpiece, and the cavities can carry coolant and clean the cutting chips. Therefore, the tool with abrasive concentration of 75 contributed to a smaller surface roughness than that with abrasive concentration of 100.…”

Section: Effects On Surface Roughnessmentioning

confidence: 99%

“…Therefore, the CFRP composites were not sharply cut, resulting in higher surface roughness. 9,36 Another possible reason was that the slots on the tool would increase the coolant flow rate, which could improve the lubrication between the tool and the workpiece. For the two-slot tool, it had both enough total cutting contact (time and area) and good lubrication.…”

Section: Effects On Surface Roughnessmentioning

confidence: 99%

“…2,[9][10][11][12] The near-net-shaped parts can be fabricated after CFRP composites' molding processes. 13,14 Additional machining processes, including hole making and surface/ edge machining, are still required to obtain the desired tolerances, dimensional precision, and shape in order to meet the application requirement including fitting and joining.…”

Section: Introductionmentioning

confidence: 99%

“…4,7,8 However, the problems of traditional surface grinding still exist in some aspects, including high cutting force, high tool wear, high surface roughness, and high cutting temperature. 3,4,7,9 It became critical to find an effective, efficient, and high-quality surface machining process for solving these problems. This article reports on such a surface machining process: rotary ultrasonic machining (RUM).…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: Effects of tool variables

Wang

Ning

et al. 2016

Advances in Mechanical Engineering

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Carbon fiber-reinforced plastic composites have many superior properties, including low density, high strength-toweight ratio, and good durability, which make them attractive in many industries. However, due to anisotropic properties, high stiffness, and high abrasiveness of carbon fibers in carbon fiber-reinforced plastic, high cutting force, high tool wear, and high surface roughness are always caused in conventional machining processes. This article reports an investigation using rotary ultrasonic machining in surface grinding of carbon fiber-reinforced plastic composites in order to develop an effective and high-quality surface grinding process. In rotary ultrasonic machining surface grinding of carbon fiber-reinforced plastic composites, tool selection is of great importance since tool variables will significantly affect output variables. In this work, the effects of tool variables, including abrasive size, abrasive concentration, number of slots, and tool end geometry, on machining performances, including the cutting force, torque, and surface roughness, are experimentally studied. The results show that lower cutting forces and torque are generated by the tool with higher abrasive size, lower abrasive concentration, and two slots. Lower surface roughness is generated by the tool with smaller abrasive size, smaller abrasive concentration, two slots, and convex end geometry. This investigation will provide guides for tool selections during rotary ultrasonic machining surface grinding of carbon fiber-reinforced plastic composites.

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Section: Effects On Surface Roughnessmentioning

confidence: 99%

Section: Effects On Surface Roughnessmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: Effects of tool variables

Wang

Ning

et al. 2016

Advances in Mechanical Engineering

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show abstract

“…To maintain the grinding temperature below permitted upper limit or the glass transition temperature of the polymer, coolant is to be applied or feed rate is to be decreased [25]. Earlier attempts were also made to decrease grinding temperature of polymer composites either by using electroplated wheel with controlled abrasive cluster [26] or by applying internal coolant through grinding wheel [27]. However, detailed mathematical model of the temperature distribution in the metal-polymer composite layered structure during grinding of its working layer has to be developed to understand the effects of different grinding and workpiece material parameters on grinding temperature to avoid grinding burns [28].…”

Section: Introductionmentioning

confidence: 99%

Modeling and analysis of temperature distribution in the multilayer metal composite structures in grinding

Pashnyov

Pimenov

Ердаков

et al. 2017

Int J Adv Manuf Technol

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The article covers a mathematical model of a temperature distribution in the three-layer metal composite structures when grinding their working layers. The computer program TEMSS, created on the basis of thermal models, allows calculation of all the characteristics of the temperature distribution in the layers of the metal composite structure, depending on the system structure, material properties of its layers, grinding and machining conditions, and duration. The work establishes the adequacy of the developed mathematical model of the temperature distribution when grinding the metal composite systems. The article covers the analysis of standard metal composite systems with Loctite, Chester molecular, and Devcon polymers on the basis of the temperature distribution model, revealing the influence of lamination on the nature of the temperature distribution. Critical temperatures are defined that determine the occurrence of thermal grinding defects in the metal composite system, including their dependencies on processing conditions and the system structure. Thus, it is found that when grinding a working steel layer of the composite system using the standard grinding conditions recommended in the reference handbooks for steel workpieces, the temperature in the working and polymer-composite layers, as a rule, exceeds the threshold values for these materials.

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Temperature effects in end milling carbon fiber reinforced polymer composites

Zhang

Wang

et al. 2016

Polymer Composites

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The temperatures at the cutting area rise excessively in machining of CFRP due to the low thermal conductivity of the material. And machining damages become aggravated with cutting-area temperatures approaching to the glass transition temperature of resin matrix. Therefore, controlling the cutting-area temperature at the suitable range is remarkably important for improving machining qualities. This article presented experimental investigations into cutting-area temperature influences on cutting force, surface integrity, as well as subsurface quality in end milling of multi-directional CFRP composites, and further discussed cutting mechanism variations. The cutting-area temperatures were controlled under three ranges by employing pressured cryogenic nitrogen gas and no coolants. The machining quality under low temperature in general was better than that under high temperature. Particularly, morphologies under high temperatures indicated fibers were bended to fracture resulting in severe subsurface damages. In contrast, the hardened matrix at low temperatures offered fibers better support, and the composites were easily squeezed to rupture which led to superior cutting performance. However, as the temperature reached extremely low, the cutting force increased dramatically and then could reduce tool life. Thus the suitable temperature range is proposed for the first time in machining CFRP. POLYM. COMPOS., 00:000-000,

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Surface grinding of carbon fiber reinforced plastic (CFRP) with an internal coolant supplied through grinding wheel

Cited by 75 publications

References 12 publications

Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: Effects of tool variables

Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: Effects of tool variables

Modeling and analysis of temperature distribution in the multilayer metal composite structures in grinding

Temperature effects in end milling carbon fiber reinforced polymer composites

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