Abstract
Carbon fiber reinforced polymers (CFRP) have got paramount importance in aerospace, and other industries due to their attractive properties of high specific strength, high specific stiffness, high corrosion resistance, and low thermal expansion. However, due to their properties like heterogeneity, anisotropy, and low heat dissipation, the issues in machining like excessive cutting forces and high surface roughness have found. In this research, a cutting force model has developed for rotary ultrasonic face milling of CFRP composites. The experimental machining was carried out on CFRP-T700. From the analysis, it has found that experimental and simulation values of cutting forces have variation/ error below than 10% in the most of the groups of parameters. However, the error found higher in few cases, due to heterogeneity, anisotropy and some other properties of these materials. The formula for contact area of the abrasive core tool improved and an overlapping cutting allowance has applied the first time. The optimal combination of parameters has investigated for cutting force and surface roughness. The developed cutting force model then further validated with pilot experiments and found the same results. So, the model developed in this paper is robust and can be applied to predict cutting force and optimization.
Highlights
Carbon fiber reinforced polymer composites have got a wide range of applications in aerospace, defense, and high-performance supporting equipment due to their attractive properties like high specific strength, high specific stiffness, low weight, high corrosion resistance, and low thermal expansion [1,2,3]
The salient features and outcomes of this research work have been recorded beneath: 1. The mechanics based cutting force prediction model has been developed for rotary ultrasonic face milling (RUFM) of Carbon fiber reinforced polymers (CFRP)-T700 composites
The improved formula for contact area, A0 have been proposed in the paper and an overlapping cutting allowance, ab has incorporated for accurate machining
Summary
Carbon fiber reinforced polymer composites have got a wide range of applications in aerospace, defense, and high-performance supporting equipment due to their attractive properties like high specific strength, high specific stiffness, low weight, high corrosion resistance, and low thermal expansion [1,2,3]. Their properties like inhomogeneity, anisotropy, and heterogeneity, are the main hindrance for their accurate and defect free machining. A review of existing literature shows that RUM has many advantages over traditional machining, such as lower cutting forces, fewer surface defects, smaller chipping size, less subsurface damage, and less tool wear [4,5]
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