Machining and machinability of fiber reinforced polymer composites

Description

Preface Contents Editors and Contributors Influence of Drill Geometry Design on Drilling-Induced Damage Reduction in Fiber-Reinforced Polymeric Composites 1 Introduction 2 Composite Materials 3 Drilling, Drill Geometry and Types 3.1 Twist Drill 3.2 One-Shot Drill 3.3 Brad-Centre, Reamer and Step Drills 4 Other Important Drill Geometry Designs 4.1 Diameters 4.2 Angles 5 General Drilling of FRP Composite Materials 6 Drilling-Induced Delamination Damage 7 The Influence of Tool Geometry 7.1 Effect of Drill Bit Geometry 7.2 Further Effects of Drill Geometry on Carbon FRP Composite Drilling 8 Numerical Simulation and Analytical Analysis 9 Recommended Design for Effective Damage Reduction 10 Conclusions and Future Perspectives 10.1 Conclusions 10.2 Future Perspectives References Thrust Force Analyses in Drilling FRP Composites 1 Introduction 2 Overview Thrust Force in Drilling of FRP Composite 3 Experimental Study of Thrust Force in Drilling FRP Composite 3.1 Effect of Cutting Parameter on Drilling Thrust Force 3.2 Effect of Tool Geometry and Material on Thrust Force Performance 4 Modelling of Cutting Forces in Drilling FRP Composite 4.1 Mechanistic Models 4.2 Critical Thrust Force Models 5 Approaches to Reduce Thrust Force/Delamination in Drilling of Composite Laminates 6 Summary References Numerical and Analytical Approaches in Machining of FRP Composites 1 Introduction 2 Modelling of Fiber Reinforced Composite Material 2.1 Constitutive Model 2.2 Damage Mechanisms 2.3 Damage Initiation Criteria 2.4 Damage Modelling 3 Analytical Approaches in Machining of Fiber Reinforced Polymer Composites 3.1 Analytical Modelling of Orthogonal Cutting 3.2 Analytical Modelling of Drilling 4 Numerical Approaches in Machining of Fiber Reinforced Polymer Composites 4.1 Numerical Modelling of Orthogonal Cutting 4.2 Numerical Modelling of Milling 4.3 Numerical Modelling of Drilling 5 Conclusion References Milling/Trimming of Carbon Fiber Reinforced Polymers (CFRP): Recent Advances in Tool Geometrical Design 1 Introduction 2 Overviews on CFRP 2.1 Types of Carbon Fiber 2.2 Fiber Forms/Architecture 2.3 Laminated/Stacked Composite 2.4 Sandwich Composite 3 Milling/Trimming of CFRP Material 3.1 Cutting Tool Material 3.2 Types of Cutting Tool for Milling/Trimming CFRP Material 3.3 Manufacturing/Grinding Processes of Solid Rod Cutting Tools 3.4 Recent Advances on the Effect of Tool Geometrical Design in Milling/Trimming of CFRP Materials 4 Conclusion References Comprehensive Study on Tool Wear During Machining of Fiber-Reinforced Polymeric Composites 1 Introduction 2 Drilling Parameters 3 Drilling Tool Materials and Geometries 4 Drilling Environments 5 Types of Drill Wear 5.1 Crater Wear 5.2 Flank Wear 5.3 Fracture or Cutting-Edge Chipping 5.4 Other Types of Wear 6 Mechanisms and Determination of Twist Drill Wear During Drilling of Composite Materials 6.1 Mechanisms of Wear 6.2 Drill Tool Life 6.3 Wear Determination or Measurement Techniques 6.4 Preventive Measures Against Rapid Drill Wear 7 Concluding Remarks and Future Perspectives 7.1 Conclusions 7.2 Future Outlooks References Milling Behavior of Injection Molded Short Fiber-Reinforced Green Composites 1 Introduction 2 Literature Review 3 Material and Methods 3.1 Fabrication of Composites 3.2 Measurements 3.3 Design of Experiment 4 Results and Discussion 4.1 Effect of Input Parameters on Induced Forces 4.2 Effect of Input Parameters on Induced Temperature 4.3 Effect of Input Parameters on Surface Roughness 4.4 Effect of Input Parameters of Burr Height 5 Conclusions References Energy Conversion and Partition in Machining Fiber Reinforced Polymer (FRP) Composites 1 Introduction 2 Energy Conversion in Machining 3 Energy Partition 4 Estimating the Various Heat Fluxes 4.1 Direct Problem for the Workpiece 4.2 Inverse Problem for the Workpiece 4.3 Sensitivity Analysis 4.4 Direct Problem for the Cutting Tool 4.5 Inverse Problem for the Cutting Tool 5 Experimental Methods 5.1 Energy Consumption 5.2 Temperatures History of the Laminate 5.3 Cutting Tool Temperatures 6 Estimated Heat Fluxes 6.1 Heat Partition into the Workpiece 6.2 Heat Partition into the Cutting Tool 6.3 Heat Partition to the Chips 6.4 Effect of Cutter Type on Heat Partition 7 Conclusions References Influence of Different Tool Materials on the Machining Performance in µED-Milling of CFRP Composites 1 Introduction 2 μED-Milling of Different Materials 3 EDM/WEDM/µEDM of CFRP 4 Experimental Details 5 Results and Discussion 5.1 Statistical Analysis of Experimental Results 5.2 Effect of Input Parameters on Machining Time 5.3 Effect of Input Parameters on the Deviation of the Channel Width 5.4 Comparative Analysis of the Copper and Brass Tools 6 Concluding Remarks References Controlled Depth Milling of Hybrid Aerospace Grade Materials Using Abrasive Water Jet – Critical Review and Analysis 1 Introduction 2 Machining Efficiency and Surface Quality 2.1 Influence of the Process Parameters 2.2 Tool Path Strategies 2.3 Prediction Models 2.4 Conclusion of the Part 3 Damage Analysis Due to Water Jet Process 3.1 Machine-Induced Defects and Damage 3.2 Grit Embedment 3.3 Conclusion of the Part 4 Post-Machining Mechanical Behaviour 4.1 Metallic Materials 4.2 Composites 4.3 Conclusion of the Part 5 General Conclusion and Perspectives References Damage to Carbon Fiber Reinforced Polymer Composites (CFRP) by Laser Machining: An Overview 1 Introduction 2 Laser Machining Strategies 3 Damage to Carbon Fiber Reinforced Polymer Composites (CFRP) by Laser Machining 4 Conclusion and Future Perspectives References Damage Response of Hybrid Fiber Reinforced Polymer Composite via SPH for Abrasive Water-Jet Cutting/Piercing 1 Introduction 2 Modelling of Piercing Behaviour- Theory and Implementation 2.1 Model Implementation 2.2 Theoretical Background 2.3 Finite Element Model 3 Results and Discussion 3.1 Qualitative and Quantitative Results of AWJ Simulation 3.2 Meso-Mechanism of AWJM for Hybrid FRP Composites Through Simulation Modelling 4 Summary References Environmental Assessment of Composite Recycling for Machining Processes and Industries 1 Introduction 2 Methodology 2.1 Goal and Scope 2.2 Material Inventory 2.3 Energy and Environmental Signature Inventory 2.4 Assumptions and Limitations 3 Results and Discussion 3.1 Environmental Impacts of Recycling Processes 3.2 Environmental Credits from Virgin Material Substitution 3.3 Recyclate Allocation Strategy for Cross Sector Applications 4 Conclusions and Future Perspective References