Machinability analysis of carbon fibre-reinforced plastics (CFRP) using compression tools

Authors

  • Somoskői Márk Balázs student
  • Norbert Geier

Keywords:

CFRP, milling, compression tool, multitooth tool, cutting force, surface roughness

Abstract

The widely spread use of polymer composites and their difficult machining behaviour have directly led to the appearance of tools with unique geometry, specialised for carbon fibre-reinforced plastics (CFRP). These so called compression tools are crafted in a way to reduce delamination, which is a common machining caused material defect. The present study focuses on the effect of technological factors on various optimization parameters in cases compression tools were used. Cutting width and feed rate have been chosen as factors. The factor levels have been determined beforehand, using central composite inscribed (CCI) design. The machining experiments were carried out on a Kondia B640 milling machine centre. A KISTLER 9257BA load cell was used for the measurement of the cutting force, likewise a Mahr Federal Pocket Surf IV instrument for surface roughness. Collected data were processed using analysis of variance (ANOVA) and response surface methodology (RSM) via Minitab 17. As a result of this research the change of tool-geometry and process parameters of CFRP machining were determined, induced by technological parameters, on two various compression tools.  It was found that the feed rate has the most significant effect on the cutting force and surface roughness, followed by the cutting width.

References

[1] M. Saleem, L. Toubal, R. Zitoune, and H. Bougherara, ‘Investigating the effect of machining processes on the mechanical behavior of composite plates with circular holes’, Compos. Part Appl. Sci. Manuf., vol. 55, no. Supplement C, pp. 169–177, 2013.
[2] C. Soutis, ‘Fibre reinforced composites in aircraft construction’, Prog. Aerosp. Sci., vol. 41, no. 2, pp. 143–151, 2005.
[3] C. Soutis, ‘Carbon fiber reinforced plastics in aircraft construction’, Mater. Sci. Eng. A, vol. 412, no. 1, pp. 171–176, 2005.
[4] R. Zitoune, V. Krishnaraj, and F. Collombet, ‘Study of drilling of composite material and aluminium stack’, Compos. Struct., vol. 92, no. 5, pp. 1246–1255, Apr. 2010.
[5] L. Sorrentino, S. Turchetta, and C. Bellini, ‘In process monitoring of cutting temperature during the drilling of FRP laminate’, Compos. Struct., vol. 168, no. Supplement C, pp. 549–561, May 2017.
[6] R. Voss, M. Henerichs, and F. Kuster, ‘Comparison of conventional drilling and orbital drilling in machining carbon fibre reinforced plastics (CFRP)’, CIRP Ann., vol. 65, no. 1, pp. 137–140, 2016.
[7] N. Geier and T. Szalay, ‘Optimisation of process parameters for the orbital and conventional drilling of uni-directional carbon fibre-reinforced polymers (UD-CFRP)’, Measurement, vol. 110, no. Supplement C, pp. 319–334, 2017.
[8] H. Wang, J. Sun, J. Li, L. Lu, and N. Li, ‘Evaluation of cutting force and cutting temperature in milling carbon fiber-reinforced polymer composites’, Int. J. Adv. Manuf. Technol., vol. 82, no. 9–12, pp. 1517–1525, Feb. 2016.
[9] M. K. N. Khairusshima, A. K. N. Aqella, and I. S. S. Sharifah, ‘Optimization of Milling Carbon Fibre Reinforced Plastic Using RSM’, Procedia Eng., vol. 184, no. Supplement C, pp. 518–528, 2017.
[10] L. Lacalle, A. Lamikiz, F. Campa, A. FDZ. Valdivielso, and I. Etxeberria, ‘Design and Test of a Multitooth Tool for CFRP Milling’, J. Compos. Mater. - J COMPOS MATER, vol. 43, pp. 3275–3290, 2009.
[11] N. Geier, ‘Machinability study of uni-directional CFRP using fractional factorial design’, Bp. Univ. Technol. Econ. TDK Study, 2015.
[12] Norbert Geier and Gyula Matyasi, ‘Machinability Study of Unidirectional CFRP Using Central Composite Design of Experiments’, Óbuda Univ. E-Bull., vol. Vol. 6, No. 1, 2016, 2016.
[13] R. Voss, L. Seeholzer, F. Kuster, and K. Wegener, ‘Influence of fibre orientation, tool geometry and process parameters on surface quality in milling of CFRP’, CIRP J. Manuf. Sci. Technol., vol. 18, no. Supplement C, pp. 75–91, 2017.

Downloads

Published

2018-09-10

Issue

Vol. 1 No. 3 (2018): Bánki Közlemények Autumn/Winter (2018)

Section

Manufacturing Technology (Gyártástechnológia)

License

Bánki Közlemények is loyal to open access for academic work. All the original articles and review papers published in this journal are free to access immediately from the date of publication. We don’t charge any fees for any reader to download articles and reviews for their own scholarly use.

The Bánki Közlemények also operates under the Creative Commons Licence CC-BY-NC-ND. This allows for the reproduction of articles, free of charge, for non-commercial use only and with the appropriate citation information. All authors publishing with the Bánki Közlemények accept these as the terms of publication.