Abstract
Although there are many machining studies of carbon and glass fiber reinforced plastics, delamination and tool wear of basalt fiber reinforced plastics (BFRP) in edge trimming has not yet studied. This paper presents an end milling study of BFRP fabricated by resin transfer molding (RTM), to evaluate delamination types at the top layer of the machined edge with different cutting conditions (cutting speed, feed rate and depth of cut) and fiber volume fraction (40% and 60%). This work quantifies delamination types, using a parameter Sd/L, that evaluates the delamination area (Sd) and the length (L), taking into account tool position in the yarn and movement of yarns during RTM process, which show the random nature of delamination. Delamination was present in all materials with 60% of fiber volume. High values of tool wear did not permit to machine the material due to an excessive delamination. Type II delamination was the most usual delamination type and depth of cut has influence on this type of delamination.
Highlights
Nowadays, aeronautical and automotive manufacturers use fiber reinforced composites, because of their properties of light weight and high strength [1]
Delamination of the top and/or the bottom layer of the composite, due to the axial tool force generated by the helix inclination angle of the milling tool is another important factor that affects dimensional precision and mechanical performance of parts
Type II delamination takes into account uncut fibers that protrude from the trimmed edge
Summary
Aeronautical and automotive manufacturers use fiber reinforced composites, because of their properties of light weight and high strength [1]. In many cases, these composites are manufactured using processes such as resin transfer molding (RTM), vacuum infusion, prepegs, etc. Edge trimming and drilling are the most extended machining processes [3]. Machining damage is unavoidable due to the high mechanical resistance of the fibers, which causes excessive tool wear and poor surface finish [4]. Type I delamination characterizes areas where the surface fibers have been broken some distance inward from the trimmed edge. Type III delamination describes fibers parallel to the machining surface
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