Abstract
Hybrid sandwich structures are more and more widely used in many industries. This is mainly due to their good properties. One of the limitations regarding the use of sandwich structures is their difficult processing. Therefore, it seems reasonable to determine the influence of cutting parameters and machining configuration on the characteristic defect (phase) formed at the boundary of the materials forming a hybrid sandwich structure. This study investigates the effects of layer orientations during milling and machining parameters such as the cutting speed Vc, the feed fz and the cutting width ae. The study is conducted on a two-layer sandwich structure composed of two materials: 2024 aluminum alloy and epoxy-carbon composite with 60% of high-strength carbon fibers. A statistical analysis is performed using the Statistica program. The results show that the change in the cutting parameters has a greater impact on the formation of a defect on the surface of samples when the machining process starts on the side of the composite rather than the metal. The highest defect value is obtained for the milling from the composite layer when the process is performed with the following cutting parameters: Vc = 300 m/min, fz = 0.08 mm/tooth, ae = 5 mm.
Highlights
Along with a very dynamic development of industries related to machine design and maintenance, the use of innovative material solutions is increasing
A deviation is observed for the variable fz = 0.12 mm/tooth for the carbon fiber-reinforced polymers (CFRP)/Al configuration
Analysing the results obtained for the sandwich structure after milling in the Al/CFRP configuration demonstrates that the value of the defect increases with increasing Vc (Vc = 80 – 400 m/min) and slightly decreases (Vc = 500 m/min)
Summary
Along with a very dynamic development of industries related to machine design and maintenance, the use of innovative material solutions is increasing. Hybrid layer structures (consisting of metal and polymer composite) have many advantages compared to analogous solid structures. Their main advantage is reduced weight and high strength properties. Such structures are characterized by high relative flexural strength and stiffness, high corrosion resistance and low thermal conductivity [5,6]. These and other advantages of this type of material mean that sandwich structures are widely used in many industries, including aviation, automotive, railway, and transport.
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