Abstract
This study presents the results of research on the surface quality of hybrid sandwich structures after milling with a diamond blade tool. It identifies the effects of feed and machining strategy on the roughness and topography of the surface. It provides an analysis of Ra and Rz surface roughness parameters as well as Sp, Sz, and Sv surface topography parameters. The processed object was a two-layer sandwich structure consisting of aluminium alloy 2024 and CFRP (carbon fibre-reinforced polymer) composite. The minimum values of the Ra and Rz surface roughness parameters were obtained on the aluminium alloy surface, whereas the maximum values were obtained on the CFRP surface. The same was true for the 3D surface roughness parameters—the lowest values of Sp, Sz, and Sv parameters were obtained on the surface of the metal layer, while the highest values were obtained on the surface of the composite layer (the maximum value of the Sp parameter was an exception). A surface topography analysis has revealed a targeted and periodic pattern of micro-irregularities for the vast majority of the samples considered. The statistical analysis shows that the surface roughness of the aluminium alloy was only affected by the feed rate. For the CFRP, the feed rate and the interaction of milling strategy and feed rate (S fz) had a statistically significant effect. The obtained results provide a basis for designing such sandwich element processing technology, for which differences in roughness and topography parameters for the component materials are lowest.
Highlights
Sandwich structures are an example of a group of engineering materials that are growing in popularity
The minimum value of the Ra surface roughness parameter obtained after treatment with the alloy 2024 (Al)/carbon fibre-reinforced polymer (CFRP) machining strategy was observed on the surface of the metal layer (0.70 μm) for fz = 0.04 mm/blade
For the CFRP/Al strategy, the highest and lowest results were obtained for the same feed rate values as for the Al/CFRP strategy: the minimum Ra value was recorded on the aluminium alloy surface (0.64 μm) for fz = 0.04 mm/blade, and the maximum was recorded on the CFRP surface (1.29 μm) for fz = 0.08 mm/blade
Summary
Sandwich structures are an example of a group of engineering materials that are growing in popularity. Their relatively low weight makes them increasingly popular in many areas of technology [1]. Sandwich structures are made up of two basic components: a thinner outer layer (face) made of a more rigid material with more favourable strength properties and a thicker and lighter inner layer (core) made of a different material. The idea behind layered material is that the faces are made of high-strength materials and the core is made of a less rigid material. The core has a relatively low density, which ensures high bending strength and high stiffness compared to the overall density of the panel—sandwich panels are typically used as structures that carry bending loads. Layered composites ensure a reduction in lateral deformation of the structure and increase its resistance to buckling [2]
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