Abstract
Carbon fibre reinforced polymer (CFRP) composites have excellent specific mechanical properties, which have contributed to the replacement of metallic structural components in high-tech sectors. However, the anisotropic and inhomogeneous properties of CFRPs render them difficult to cut. Burr is one of the main machining-induced macro-geometrical defects in CFRPs. Even though burr does not weaken the resultant strength of the composites (unlike delamination), its removal is time-consuming and costly. The main aim of the present paper is to investigate the efficiency of the mechanical deburring method. Deburring experiments were carried out on unidirectional CFRP, based on a full factorial experimental design using a special solid carbide cutting tool. The effects of feed and cutting speed were analysed using digital image processing and visual evaluation of high-resolution images. The experimental results show that the examined factors seem to have no significant effect on the results over the applied parameter range, because the exit burrs were successfully removed at each parameter setting. Furthermore, during the deburring process, the formation of a significant amount of chamfers was observed. Since the size of the chamfers depends on the size of delamination-induced material deformation and process control, it should be either compensated for or monitored in the future to develop a more reliable deburring process.
Highlights
Nowadays, carbon fibre reinforced polymer (CFRP) composites make up a significant proportion of materials used in the automotive, defence, aerospace, marine and space technology industries where it is almost indispensable [?]
The efficiency of mechanical deburring was examined in this study on drilling-induced exit burrs by comparing the parameters Ab0 and Ab
The efficiency of mechanical deburring was examined by digital image processing
Summary
Carbon fibre reinforced polymer (CFRP) composites make up a significant proportion of materials used in the automotive, defence, aerospace, marine and space technology industries where it is almost indispensable [?]. The reason for their popularity is due to the fact that they have excellent mechanical properties, their anisotropic and inhomogeneous properties cause major problems like delamination, microcracks and burrs which have to be solved in machining. Jia et al [?] examined the effect of the machining direction at the working point They observed that in the absence of an external supporting plate, the machining is bending-dominated and the probability of uncut fibres and burrs forming increased. If the fibre is supported by either a plate or a material, the machining is fracture-dominated and the possibility of surface damage is minimal
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