Abstract
Machining of CFRP composites is usually described as a challenging process from tool life and surface quality perspectives. To achieve a flawless machined surface at reasonable cutting tool life/cost, an optimum combination of cutting tool material and geometry is the key. The cutting tool angles are of importance as these dictate the cutting mechanism as well as the cutting edge robustness and the introduction of vibration to the machining process opens up new horizons of improvement and stirs further research questions. This article investigates the effect of tools with different geometry possessing different rake angles when used in ultrasonic-assisted edge trimming operation dealing with multidirectional CFRP laminates. A full-factorial experimental design was adopted to analyze the effect of process parameters typically cutting speed, feed rate, rake angle, amplitude, and their interactions. Machining performance indicators were captured which were the cutting forces, tool wear, chip temperature, and surface roughness. The results showed that UAM mode contributed to an increase in the cutting forces, tool wear, and chip temperature compared to the conventional mode. On the other hand, UAM mode improved the quality of the machined surface. Additionally, the ultrasonic mode enhanced the material removal mechanism using a tool with a negative rake angle.
Highlights
Lightweighting is one of the main drivers behind the growing demand for carbon fiber reinforced plastics (CFRP) composites
The multidirectional CFRP laminates used in this investigation were autoclave cured stack of unidirectional (UD) prepregs containing intermediate modulus (294 GPa) carbon fibers impregnated within an epoxy resin matrix
This article presented an investigation into the effect of tool geometrical features, having different rake angles, on the surface integrity of multidirectional CFRP laminates during the ultrasonic-assisted edge trimming process
Summary
Lightweighting is one of the main drivers behind the growing demand for carbon fiber reinforced plastics (CFRP) composites. Cutting by conventional need to overcome the challenging heterogeneity and anisotropy of the CFRP laminates and the machining induced damage [5] This is found in many forms/locations either at free edges such as fibre pull-out and delamination or in form of on/sub-surface such as fibre pull-out and matrix smearing or degradation [6]. Defects and their costly scrap toll were the motive to study the factors affecting these damages in order to eliminate/mitigate for the first-time-right or zero-defect production concepts. For a unidirectional CFRP laminate, the defects generated from cutting are mainly influenced by the cutting direction corresponding to the fiber orientations (fibre cutting angle) [9, 10]
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