Abstract
Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industrial fields such as aerospace, automotive, and shipping industries due to their excellent mechanical properties that lead to enhanced functional performance. In this paper, an experimental study on edge trimming of CFRP was done with various cutting conditions and different geometry of tools such as helical-, fluted-, and burr-type tools. The investigation involves the measurement of cutting forces for the different machining conditions and its effect on the surface quality of the trimmed edges. The modern cutting tools (router tools or burr tools) selected for machining CFRPs, have complex geometries in cutting edges and surfaces, and therefore a traditional method of direct tool wear evaluation is not applicable. An acoustic emission (AE) sensing was employed for on-line monitoring of the performance of router tools to determine the relationship between AE signal and length of machining for different kinds of geometry of tools. The investigation showed that the router tool with a flat cutting edge has better performance by generating lower cutting force and better surface finish with no delamination on trimmed edges. The mathematical modeling for the prediction of cutting forces was also done using Artificial Neural Network and Regression Analysis.
Highlights
Carbon Fiber reinforced polymers have been extensively used in aerospace, transportation, robotics, sporting goods, construction, medical, and military applications due to its high strength-to-weight ratio and high modulus-to-weight ratio [1]
The cutting cuttingforce force generated during the trimming edge trimming due tocutting various cutting and tool geometries measuredwas using the Kistler milling tool dynamometer
It was found that the tool T1 generated lower cutting force and moderate surface roughness
Summary
Carbon Fiber reinforced polymers have been extensively used in aerospace, transportation, robotics, sporting goods, construction, medical, and military applications due to its high strength-to-weight ratio and high modulus-to-weight ratio [1]. CFRP composites contain two phases of materials with significantly distinguished mechanical and thermal properties, causing complex interactions between the matrix and the reinforcement during machining. In CFRP composites, the reinforcement is carbon fiber [2] and the matrix is usually a polymer resin—such as epoxy—which provides the strength to bind the reinforcements together. Even though composite components are often made to near-net shapes, after demolding some post-machining operations are often unavoidable, like drilling and trimming. These operations must be performed to assure that the composite parts meet dimensional tolerance, surface quality, and other functional requirements [3].
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