Machining Of Composite Materials Research Articles

An Extensive Study of Metal Matrix Composites and their Various Properties for Different Uses

This study examines the creation and development of composite materials, from conventional techniques to their innovative uses in numerous industries. Composite materials that are robust, versatile, and resilient have advanced significantly, especially with the application of nanotechnology and hybrid fiber reinforcements. Composite materials are difficult to machine due to their anisotropic and non-homogeneous structure, as well as the high abrasiveness of their reinforcing parts. This typically results in the workpiece becoming damaged and the cutting tool wearing down very rapidly. On composite materials, traditional machining methods such as turning, drilling, and milling can be applied with the appropriate tool design and operating parameters. An overview of the various issues related to the conventional machining of the main types of composite materials is given in this work. This article examines novel matrix materials, forms of reinforcement, and production procedures to show how advanced metallic matrix nano composites and fiber-reinforced polymers are replacing traditional composites. Special emphasis is given to the strict manufacturing conditions in addition to the homogenous dispersion of nanoparticles and damage-free machining of fiber composite materials. The essay also discusses how sustainable alternatives, including reinforcements made of natural fibers, affect the ecosystem. This study aims to offer a comprehensive analysis and case studies.

Effect of Cutting Conditions on the Size of Dust Particles Generated during Milling of Carbon Fibre-Reinforced Composite Materials.

Conventional dry machining (without process media) of carbon fibre composite materials (CFRP) produces tiny chips/dust particles that float in the air and cause health hazards to the machining operator. The present study investigates the effect of cutting conditions (cutting speed, feed per tooth and depth of cut) during CFRP milling on the size, shape and amount of harmful dust particles. For the present study, one type of cutting tool (CVD diamond-coated carbide) was used directly for machining CFRP. The analysis of harmful dust particles was carried out on a Tescan Mira 3 (Tescan, Brno, Czech Republic) scanning electron microscope and a Keyence VK-X 1000 (Keyence, Itasca, IL, USA) confocal microscope. The results show that with the combination of higher feed per tooth (mm) and lower cutting speed, for specific CFRP materials, the size and shape of harmful dust particles is reduced. Particles ranging in size from 2.2 to 99 μm were deposited on the filters. Smaller particles were retained on the tool body (1.7 to 40 μm). Similar particle sizes were deposited on the machine and in the work area.

Monitoring Equipment Malfunctions in Composite Material Machining: Acoustic Emission-Based Approach for Abrasive Waterjet Cutting

This paper introduces an Acoustic Emission (AE)-based monitoring method designed for supervising the Abrasive Waterjet Cutting (AWJC) process, with a specific focus on the precision cutting of Carbon Fiber-Reinforced Polymer (CFRP). In industries dealing with complex CFRP components, like the aerospace, automotive, or medical sectors, preventing cutting system malfunctions is very important. This proposed monitoring method addresses issues such as reductions or interruptions in the abrasive flow rate, the clogging of the cutting head with abrasive particles, the wear of cutting system components, and drops in the water pressure. Mathematical regression models were developed to predict the root mean square of the AE signal. The signal characteristics are determined, considering key cutting parameters like the water pressure, abrasive mass flow rate, feed rate, and material thickness. Monitoring is conducted at both the cutting head and on the CFRP workpiece. The efficacy of the proposed monitoring method was validated through experimental tests, confirming its utility in maintaining precision and operational integrity in AWJC processes applied to CFRP materials. Integrating the proposed monitoring technique within the framework of digitalization and Industry 4.0/5.0 establishes the basis for advanced technologies such as Sensor Integration, Data Analytics and AI, Digital Twin Technology, Cloud and Edge Computing, MES and ERP Integration, and Human-Machine Interface. This integration enhances operational efficiency, quality control, and predictive maintenance in the AWJC process.

CUTTING FORCE OPTIMIZATION OF MACHINING OF KEVLAR (K-129) FIBER REINFORCED PLASTIC COMPOSITES MATERIALS

Machining of composite materials presents challenges due to the material's abrasive reinforcement as well as its anisotropic and nonhomogeneous properties. Near-net-shape composite goods are typically made, however machining techniques such as milling or drilling are routinely utilized for dimensional precision and assembly purposes. Laminate of Kevlar epoxy is made by hand lay-up. On a Beaver Milling Machine, laminates are cut orthogonally using a single-point carbide cutting tool with different rake angles. Cutting forces were measured at different cutting speed and depth of cut. It is critical to accurately forecast cutting forces during the machining process of fiber-reinforced polymer composites in order to design and improve such processes. The aim is to reduce the cutting force required to a minimum. Response surface methodology was employed for modeling and optimization. Additional experiments corroborate the findings.

InAsSb Photodiode Fibre Optic Thermometry for High-Speed, near-Ambient Temperature Measurements

Infrared radiation thermometers (IRTs) overcome many of the limitations of thermocouples, particularly responsiveness and calibration drift. The main challenge with radiation thermometry is the fast and reliable measurement of temperatures close to room temperature. A new IRT which is sensitive to wavelengths between 3 μm and 11 μm was developed and tested in a laboratory setting. It is based on an uncooled indium arsenide antimony (InAsSb) photodiode, a transimpedance amplifier, and a silver halogenide fibre optic cable transmissive in the mid- to long-wave infrared region. The prototype IRT was capable of measuring temperatures between 35 °C and 100 °C at an integration time of 5 ms and a temperature range between 40 °C and 100 °C at an integration time of 1 ms, with a root mean square (RMS) noise level of less than 0.5 °C. The thermometer was calibrated against Planck’s law using a five-point calibration, leading to a measurement uncertainty within ±1.5 °C over the aforementioned temperature range. The thermometer was tested against a thermocouple during drilling operations of polyether ether ketone (PEEK) plastic to measure the temperature of the drill bit during the material removal process. Future versions of the thermometer are intended to be used as a thermocouple replacement in high-speed, near-ambient temperature measurement applications, such as electric motor condition monitoring; battery protection; and machining of polymers and composite materials, such as carbon-fibre-reinforced plastic (CFRP).

Recent Advances in Machining of Composite Materials by Electrical Discharge Machine

Composites are being used since decades and imparting excellent properties comparatively. It may be used in numerous industries because of its light weight and specific strength. Machinability of these materials is a concerned aspect. Conventional and The composites have been machined using unconventional machining techniques. Conventional methods are less suitable than non-conventional quoting the best surface finish and ability to machine complex parts. This article investigates the suitability of thermo-electric process for the machining of composites for higher surface quality and material removal. It includes the study of machining by die sinking, wire cut, powder mixed electric discharge machine in different matrix based composites along with the variation of reinforcement. Electric Discharge Machining (EDM) finds its suitability in machining of different metal matrix composites (MMC) more than the Polymer Matrix Composite (PMC) and Ceramic Matrix Composites (CMC). Variation in input parameters listed as Pulse duration, Voltage, Peak Current and Polarity is studied to obtain the optimum resulting parameters as Material Removal Rate (MRR), Surface Roughness (SR), Electrode Wear Rate (EWR) and Kerf Width. Material removal in PMC is 16% more in parallel fibre direction than with perpendicular. Low electrical conductance and high hardness of CMCs limits the use of EDM while natural ceramics are found more suitable for machining. Gap voltage, pulse on time and current are found most crucial in machining MMCs while quantifying material removal and surface roughness.

A Review Study on Non - Traditional Machining of Composite Materials

A Review Study on Non - Traditional Machining of Composite Materials

Dynamic Modeling and Performance Evaluation of a 5-DOF Hybrid Robot for Composite Material Machining

Dynamic performance is an important performance of robots used for machine processing. This paper studies the dynamic modeling and evaluation method of a 5-DOF (Degree of Freedom) hybrid robot used in aerospace composite material processing. With the consideration of the dynamics of the serial part, the complete dynamic model of the hybrid robot is established based on the virtual work principle. In addition to the widely considered acceleration term, a dynamic performance evaluation index that comprehensively considers the acceleration term, velocity term and gravity term in the dynamic model is proposed. Using the dynamic performance index, the effect of the placement direction of the robot and the arrangement of the double symmetric limbs on robot dynamics are investigated. The results indicate that the vertical placement is beneficial to the dynamics of the hybrid robot, and the arrangement of double symmetric limbs has different effects on different limbs.

Методика критериального анализа мультивариантных систем

Introduction. Trends in the development and application of modern machine-building systems somehow create the problem of analysis and choice in the presence of alternative objects, or with a large number of comparison criteria - indicators of the effectiveness of objects or systems. The main difficulties in optimizing the solution for designing production systems depend on complex technological problems: a large number of influencing factors and the absence of patterns. The choice of effective objects and systems is often a complex and multi-criteria process that requires a lot of time and, as a result, reduces the efficiency of the organization of production preparation. In this regard, for the preparation and adoption of technical and economic decisions of various complexity in production conditions, a systematic approach is required using the most rational forms and methods of organizing production. The purpose of the work: to create a generalized methodology for the criteria analysis of multivariant systems. The methods of investigation. A methodology is proposed aimed at improving the efficiency of the organization of pre-production due to a reasonable choice from a large number of options. The choice of a rational solution option is based on the ranking of indicators by priority at the time of making a reasonable decision in a specific situation and the type of object and system under consideration. Indicators can be variable, taking into account the specifics of production. Results and Discussion. A comparative analysis of the process of edge cutting machining of the STEF-1 fiber-glass polymer composite material with an interlocking side mill carrying various insert materials is conducted as an example of the practical application of the proposed methodology. As comparison parameters, the period of technological tool life, cutting performance and reduced costs in the implementation of cutting are taken. According to the results of a comparative multi-criteria analysis carried out according to the presented method, it follows that the priority in the system under consideration with the specified parameters for the implementation of the technology is the tool equipped with WC–3Co alloy inserts, which has the highest value of the weight criteria coefficient. According to the results of the analysis, a tool equipped with WC–2TaC–6Co alloy inserts is close in rationality, which allows recommending it as an analogue when choosing. The scope of the proposed application of the methodology is seen if it is necessary to analyze complex multivariant systems/objects. The objects/systems can be both variants of scientific solutions under various conditions of comparability, as well as design, technological solutions, structural and instrumental materials at the selection stage in the design and technological preparation of production, variants of the system implementation algorithm. The comparison parameters can be physical, mechanical, technological, operational properties; technical, economic and quality indicators; specific characteristics and parameters. The proposed technique will reduce the time for making new decisions under varying production conditions. The use of the methodology with known and well-defined parameters characterizing multivariant systems makes it possible to algorithmize, and subsequently automate, the process of organizational and technological preparation of production.

An Integrated RSM - improved salp swarm algorithm for quality characteristics in AWJM of Ananas comosus-HIPS composites

Natural fiber based polymer composite materials are increasingly used in wider applications due to their low weight and improved mechanical qualities. However, due to their inherent heterogeneity, anisotropy, and temperature sensitivity, traditional machining of composite materials is difficult. Abrasive water jet (AWJ) cutting is a non-traditional machining technique that has recently been used to fabricate polymer matrix component parts. Therefore, this study focuses on the machinability of ananas comosus–high impact polystyrene composites (each wt50%) using the AWJ process. The experiments were conducted and analyzed using central composite design (four-factor, five-level) and the response surface methodology, respectively. The mathematical models between process parameters, kerf inclination, entry delamination factor (DF) and exit DF were established and confirmed by verification. Analysis of variance was utilized to examine the influence of each input parameter on the responses. The AWJ machined surfaces were examined using a SEM images. Further, the developed models were coupled to the improved salp swarm algorithm, which was used to find the best cutting parameters for the minimizing of kerf inclination, entry DF, and exit DF, which are all important quality aspects. During the confirmatory tests, only minor differences (less than 2%) between the predicted and experimental results were observed.

Estimating of cutting force and surface roughness in turning of GFRP composites with different orientation angles using artificial neural network

Abstract Glass fiber-reinforced polymer (GFRP) composite materials are widely used in many manufacturing industries due to their low density and high strength properties, and consequently, the need for precision machining of such composites has significantly increased. Since composite materials have an anisotropic and heterogeneous structure, the machinability of composite materials is quite different from conventional materials. In the machining of GFRP composite pipes, tool wear, cracks or delamination, a rough surface, etc., many unwanted problems may occur. Therefore, GFRP composite pipes are difficult to process. To prevent such problems, it is very crucial to select suitable process parameters, thereby achieving the maximum performance for the desired dimensional integrity. In this study, through turning of GFRP composites with different orientation angles (30°, 60°, and 90°), the effects of cutting speed (50, 100, and 150 m·min−1), feed rate (0.1, 0.2, and 03 mm·rev−1), and depth of cut (1, 2, and 3 mm) on cutting force and surface roughness were determined. Then, with the use of these machining parameters, a model of the system for determining cutting force and surface roughness was established with artificial neural networks (ANNs). The ANN was trained using Levenberg–Marquardt backpropagation algorithm. It has been observed that the results obtained with the ANN model are very close to the data found in experimental studies. In both experimental and model-based analysis, minimum cutting force (44 N) and surface roughness (2.22 µm) were achieved at low fiber orientation angle (30°), low feed rate (0.1 mm·rev−1), and depth of cut (1 mm) at high cutting speeds (150 m·min−1).

Effect of laser pulse energy deposition method on nanosecond laser scanning ablation of SiCp/AA2024 composites

The control of the thermal stress and heat accumulation is major issue faced in the laser precision machining, and plays a key role in the laser machining of composite materials. In this pursuit, the present study envisaged the effect of pulse energy deposition method on the processing of particulate reinforced aluminum alloy matrix composites SiCp/AA2024. Specifically, by modulating the combination of the spot overlap ratio (SOR) and the area scanning passes, a variety of pulse energy deposition methods with the same number of received pulses per unit area were designed and applied on a target. The influence of the pulse energy deposition on processing was evaluated by measuring and comparing the ablation depth and surface roughness. The results showed that by using multiple scanning passes with small spot overlap ratios led to a good processing with a high ablation depth. Furthermore, the influence of SOR and scanning passes on the machining was studied using the control variable method. The influence of energy deposition method was studied from the aspect of nanosecond laser ablation mechanism, Fresnel reflection effect and heat accumulation.

Evaluation of Machinability of Cu Matrix Composite Materials by Computer Numerical Control Milling under Cryogenic LN2 and Minimum Quantity Lubrication

Evaluation of Machinability of Cu Matrix Composite Materials by Computer Numerical Control Milling under Cryogenic LN2 and Minimum Quantity Lubrication

Experimental study on abrasive water jet machining of WCFC reinforced flax/wire mesh/hemp composite

Conventional machining of composite material was challenging due to delamination, tool wear, fiber pull-out, spalling, fiber fraying, heat generation, and excessive stresses. The non-conventional machining process was preferred for high-strength materials to produce complicated shapes with a better surface finish. This research describes an experimental analysis of abrasive water jet machining (AWJM) on flax/wire mesh/hemp reinforced epoxy composite. In addition, recycling of waste carbon fiber composite (WCFC) was also practiced and reused as a filler particle along with the fabricated hybrid composite. The hybrid composite was fabricated using the hand layup technique with 20.3 wt% of fiber, 10.5 wt% of wire mesh, and 2 wt% of WCFC. Experiments were conducted to evaluate the influence of standoff distance, traverse speed, and abrasive mass flow rate on the output responses such as kerf angle (θ) and surface roughness (Ra). The design of experiments found that surface finish was improved with optimum process parameters. It was detected that spalling defects, wear track, and micro-cutting were noteworthy in the machined hybrid composite concerning high standoff distance and abrasive mass flow rate. Morphological study in the cut surface of the hybrid composite was analyzed through a scanning electron microscope (SEM), and the fiber characterization was done through Fourier-transform infrared spectroscopy (FTIR).

THE ORIENTATION ANGLE OF REINFORCING ELEMENTS INFLUENCE ON TOOL WEAR INTENSITY IN PROCESSING POLYMER COMPOSITES

The relative angle between the direction of the reinforcing fibers and the cutting speed vector, defined as the angle of the reinforcing elements orientation, has a significant impact on the chip formation mode, cutting forces and the final surface quality. During machining of polymer composite materials, high-intensity wear occurs along the flank surface. This paper presents an analysis of the problem of the orientation fibers angle influence in a polymer composite on the cutting tool wear rate. For the previously proposed hereditary-aging model of tool weight loss due to wear, it is proposed to take into account the influence of the reinforcement angle through the dependence of the contact pressure and friction coefficient on this parameter. The article develops a generalizing model for practical consideration of the known in advance angle of reinforcement to predict tool wear and tool life during of polymer composite materials machining.

Molybdenum copper based ultrathin two-phase heat transport system for high power-density gallium nitride chips

• Design of metal matrix composite enables creation of ultrathin heat transport device. • Ultrathin devices integrated with microchip for low-thermal-resistance heat removal. • The thermal conductivity of the device reaches 10200 W/(m·K) under large heat flux. • Low-stress encapsulation for high power-density chip cooling systems is highlighted. Metal matrix composite based ultrathin two-phase heat transport devices with excellent thermal conductivity and low thermal expansion can address heat dissipating issues and thermal expansion mismatch-induced mechanical failures in the high-power-density micro-electronic systems. Due to the difficulties in processing metal matrix composites, however, achieving the fabrication of the ultrathin devices and their reliable integration with semiconductor chips has challenges. The precision machining and surface engineering of composite materials address the difficulties in processing metal matrix composite based ultrathin devices and contribute to reliable welding encapsulation of the chip. Here, we generate an ultrathin (≤1 mm) metal matrix composite based two-phase heat transport device with low thermal expansion and integrate such device with the gallium nitride chip. The sandwich-structured molybdenum (Mo) copper (Cu) composite, Cu-MoCu-Cu, is used as the casing material of the hermetically welded device. The Mo-Cu based two-phase heat transport device demonstrates an extremely low thermal resistance, which is 95% lower than that of the Cu plate. This device with superior thermal conductivity of 10200 W∙m −1 ∙K −1 enables the stable operation of the high-power-density (7.9 × 10 2 W/cm 2 ) gallium nitride micro-chip within the safe operating temperature range (20–175 °C). In addition, the Mo-Cu based device also helps reduce the thermal stress generated at the encapsulation interface by 39% compared to Cu cooling plate, and thus mitigates the fatigue risks of the device. This chip-level integration of heat transport system using the metal matrix composite-based ultrathin two-phase heat transport devices offers new opportunities in the integration of high heat dissipation and low-stress encapsulation in compact electronic systems.

Design and Analysis of Hollow Catenoidal Horn Profile for Ultrasonic Machining of Composite Materials

The composite materials Si/AlC, crystal quartz, and ceramic glass are becoming an important part of the present society in many engineering and non-engineering fields. Conventional methods available for machining these materials have many flaws due to which their application on large scale is restricted. A non-conventional process known as ultrasonic machining (USM), can be implemented for machining of these materials effectively. Anyhow machining efficiency of USM greatly depends upon its horn design and therefore in the present study a horn based on a catenoidal profile with aluminum and titanium material for USM was designed and developed by using solid works and ANSYS. Modal and harmonic analysis was done on the horn for computation of various parameters of interest such as resonant frequency, amplitude vibration and equivalent stresses. After the computation of the results, they were analyzed and compared with those available in the literature in terms of stresses and magnification factor for their validation comparison with literature, it was found that an aluminum catenoidal horn shows higher magnification with the least stress magnitude as compared to horns avail-able in the literature and hence can be used in USM as a replacement for existing horns.

Erosion model for abrasive water jet machining of composite materials

Erosion model for abrasive water jet machining of composite materials

An experimental and empirical assessment of machining damage of hybrid glass-carbon FRP composite during abrasive water jet machining

Fiber reinforced polymer (FRP) composite materials have huge demand in various fields due to their low weight and better mechanical qualities. Machining of FRP composite materials without damage is quite difficult using traditional machining systems owing to their intrinsic anisotropy, heterogeneity, and temperature sensitivity. Abrasive water jet machining (AWJM) is a known versatile technique to address the machining of FRP composite with minimal damage. However, kerf taper and delamination are the significant damages usually recorded in AWJM. The present work aims to minimize the above-said damages by applying a hybrid grey relational analysis (GRA)-principal component analysis (PCA) mathematical model. The glass and carbon fibers are used as reinforcements in the epoxy matrix. Nine experiments are conducted by considering hydraulic pressure, the mass flow of abrasive, standoff distance and transverse speed as machining parameters at three different levels each. The experimental and empirical results reveal that the mass flow of abrasive and hydraulic pressure are significant parameters to minimize the kerf damage, whereas the mass flow of abrasive and standoff distance are the parameters to reduce the delamination damage. The confirmation experiment based on the recommended optimized parameter records the reduction in delamination damage and kerf width damage to 33.9% and 11.72%, respectively. The adequacy and accuracy of the proposed mathematical model is being performed with the value of indicators R2 and adjR2, which are all closer to one.

Wear mechanism and quantification of polycrystalline diamond milling cutter in high speed trimming of carbon fiber reinforced epoxy

The use of polycrystalline diamond cutters (PCD) in machining of composite material is increasing. Understanding their wear mechanism and clarity on wear measurement methodology will lead to their productive usage and cost justification. This study focuses on understanding wear in PCD milling cutters at the micro, macro level, and its physical characterization when employed for fibrous composite machining. This leads to the development of a proposal for a clear methodology on consistent wear measurement, which includes a suitable selection of techniques and identification of wear parameters. Continuous diamond skeleton structure made during binder infiltration is captured in worn out PCD edge with the help of scanning electron microscopy. Overall wear process appears to be a complex mixture of losing binder, smaller grains, and pieces of continuous diamond skeleton. This results in cavities of various shapes and forms on the cutting edge making substantial variations in edge recession and edge width. After analyzing, different tool parameters, it was found out that the distance from apex to edge roundness of clearance or rake face is a reliable and repeatable wear parameter. These are shown to be comparable between different wear locations, flutes, and tools suggesting higher wear predictive capabilities. Among different techniques, three-dimensional high-resolution profile scanning of the cutter has been identified as the most efficient tool for tracking wear at regular intervals in tool life prediction studies.