Machinability of Fibre-Reinforced Plastics

Description

ADVANCED COMPOSITES SERIES Presents polymer-based fibre reinforced composite materials and addresses the characteristics of these widely used materials like low density and coefficient of thermal expansion, specific strength with better fatigue resistance and modulus. The topics discussed are laser-based material machining, high-speed robotic end milling and LFRP modeling, including definitions, features, machine elements (system set-up) as well as experimental and theoretical investigations. These investigations include effects of input variables (tool rotation speed, feed rate and ultrasonic power) on cutting force, torque, cutting temperature, edge quality, surface roughness, burning of machined surface, tool wear, material removal rate, power consumption and feasible regions. Further a detailed literature review on drilling polymer composites with a focus on delamination is included. Aspects such as delamination mechanisms, fabrication methods, the type of drilling process adopted by various researchers, cutting parameters employed during drilling, mathematical delamination modelling, effect of thrust force, spindle speed, thermal loads, tool wear, surface roughness, tool geometry and tool materials on delamination and hole quality are summarized. In addition an approach of digital image processing in delamination assessment completes the approach. - Discusses Carbon Fiber Reinforced Plastics modern technologies for automated, highly productive and cost efficient processing. - Great value for final undergraduate engineering courses or as a topic on manufacturing with FRPs at the postgraduate level as well as a useful reference for academics, researchers, manufacturing, mechanical and materials engineers, professionals in machining of FRPs and related industries. Carbon Fiber Reinforced Plastics modern technologies for automated, highly productive and cost efficient processing Robots offer cutting-edge and lower-cost solutions than machine tools for bringing molded CFRP parts to their final shapes and sizes. Preface Contents List of contributing authors 1 Laser material machining of CFRP – an option for damage-free and flexible CFRP processing? 1.1 Introduction 1.2 State of the art of machining of CFRP 1.2.1 Cutting CFRP 1.2.2 Surface pre-treatment of CFRP 1.2.3 Shape cutting of CFRP 1.3 Laser material interaction 1.4 Laser material machining of CFRP 1.4.1 Laser cutting of CFRP 1.4.2 Laser surface pre-treatment of CFRP 1.4.3 Laser ablation of CFRP 1.5 Conclusion 2 Rotary ultrasonic machining of CFRP composites 2.1 Introduction 2.1.1 CFRP composites 2.1.2 Rotary ultrasonic machining 2.1.3 Purpose of this chapter 2.2 Rotary ultrasonic machining system set-up 2.2.1 Ultrasonic power supply 2.2.2 Ultrasonic transducer 2.2.3 Ultrasonic amplitude transformer (horn) and tool holder 2.2.4 Cutting tool 2.3 Input variables and output variables in RUM 2.3.1 Machining variables 2.3.2 Cutting tool variables and cooling variables 2.3.3 Workpiece properties 2.3.4 Output variables 2.4 Effects of input variables on output variables 2.4.1 Effects on cutting force 2.4.2 Effects on torque 2.4.3 Effects on cutting temperature 2.4.4 Effects on edge quality 2.4.5 Effects on surface roughness 2.4.6 Effects on burning of machined surface 2.4.7 Effects on tool wear 2.4.8 Effects on MRR 2.4.9 Effects on power consumption 2.4.10 Effects on feasible regions 2.5 Summary 3 High-speed robotic trimming of CFRP 3.1 Introduction 3.2 Machinability of CFRP 3.2.1 Evaluation of the cutting force 3.2.2 Assessment of the machinability of CFRP under high-speed robotic trimming 3.2.3 Cutting forces for robotic trimming experiments 3.2.4 Quality of robotic trimmed specimens 3.2.5 Surface quality 3.3 Conclusion 4 Numerical modeling of LFRP machining 4.1 Introduction 4.2 Orthogonal cutting 4.2.1 2D modeling 4.2.2 3D modeling 4.2.3 Thermal effects 4.3 Drilling 4.3.1 Comparison between simplified and complete drilling models 4.3.2 Thermal model of drilling 4.4 Conclusions 5 Delamination in composite materials: measurement, assessment and prediction 5.1 Introduction 5.2 Mechanisms of delamination 5.2.1 Peel-up delamination 5.2.2 Push-out delamination 5.3 Measurement of delamination 5.3.1 Visual methods 5.3.2 Image processing 5.3.3 Acoustic emission 5.3.4 Scanning acoustic microscopy (SAM) 5.3.5 Ultrasonic C-scan 5.3.6 Radiography 5.3.7 X-ray computerized tomography 5.3.8 Shadow moiré interferometry 5.4 Assessment of delamination 5.4.1 Delamination factor/conventional delamination factor 5.4.2 Delamination size 5.4.3 Two-dimensional delamination factor (Fd) 5.4.4 Damage ratio 5.4.5 Delamination factor 5.4.6 Adjusted delamination factor 5.4.7 Equivalent delamination factor 5.4.8 Refined delamination factor (FDR) 5.4.9 Shape circularity ( f) 5.4.10 Minimum delamination factor 5.5 Delamination in milling 5.6 Numerical prediction of delamination 5.6.1 Regression analysis 5.6.2 Artificial neural network (ANN) 5.6.3 FE simulation methods 5.7 Summary 6 Drilling of high impact polystyrene composites materials 6.1 Introduction 6.2 Materials and Manufacturing 6.3 Experimental work 6.4 Response surface methodology-based modeling of process parameters 6.5 Results and Discussion 6.6 Conclusions 7 A review on investigations in drilling of fiber reinforced plastics 7.1 Introduction 7.1.1 Delamination and delamination mechanism 7.1.2 Fabrication of polymer matrix composites 7.2 Drilling process 7.2.1 Delamination assessment 7.2.2 Effect of various machining parameters on delamination 7.3 Role of digital image processing in delamination assessment 7.4 Summary Index