Abstract
Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.
Highlights
Carbon Fiber Reinforced Polymer laminates (CFRPs) have been widely used in recent years in different industrial applications, such as the aerospace or automotive industries, due to their excellent mechanical properties and low density [1].CFRPs are classified as difficult to cut due to the presence of hard fibers, which can cause mechanical wear to cutting tools and their inhomogeneity and their anisotropic material properties [2,3]
This work focused on the experimental study of orthogonal cutting, with a linear movement at a high cutting speed, of a multidirectional CFRP laminate to analyze the influence of tool geometry and cutting parameters on material damage
Results and Discussion remove the powder-like chip particles generated during the machining of CFRP
Summary
Carbon Fiber Reinforced Polymer laminates (CFRPs) have been widely used in recent years in different industrial applications, such as the aerospace or automotive industries, due to their excellent mechanical properties and low density [1]. Many numerical models found in the literature have been developed to simulate machining processes, which involve rotary cutting movements, such as turning [17,18] or drilling [19] In these cases, it is difficult to obtain experimental information about the effect of the orientation of the fibers on the tool and on the workpiece, so the differences between the experimental test and the conditions considered in the model definition reduce the precision of the model. This work focused on the experimental study of orthogonal cutting, with a linear movement at a high cutting speed, of a multidirectional CFRP laminate to analyze the influence of tool geometry and cutting parameters on material damage. The surface quality was determined with an optical microscope to analyze the damage, and the contact forces were measured during the orthogonal cutting
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