5 Influence of milling process parameters on the surface quality of GFRP composites
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Abstract
The intensified stiffness and lightweight structural designed components such as glass fibre-reinforced plastic (GFRP) composites are becoming an alternative to metallic materials to improve the performance of aircraft, shipbuilding and automobiles. Machining damages on the machined texture or subsurface due to the catastrophic nature of composites result in rejection of components at the last stage of production cycle, and necessitate the minimization of such damages by improving the manufacturing quality in secondary manufacturing process. In this chapter, various fibre orientation (FO) angled GFRP workpieces were milled with different tool rake angles (RA) of end milling cutters. Random experiments were done to test the effects of important milling parameters, such as spindle speed, depth of cut (DOC), FO angle and tool’s RA. The machined wall surface and subsurface were thoroughly analyzed by scanning electron microscope. A reasonable reduction in subsurface damages was observed when using the DOC is low (1 mm) and FO angle of workpiece is less than 90°. At this instance, the machining force and the surface roughness are increased proportionally to a DOC, FO angle of the workpiece and tool RAs, where the surface damages were found to be more. It has also been observed that the damage mechanisms of GFRP composite laminates were dominated by their FO angle.
Abstract
The intensified stiffness and lightweight structural designed components such as glass fibre-reinforced plastic (GFRP) composites are becoming an alternative to metallic materials to improve the performance of aircraft, shipbuilding and automobiles. Machining damages on the machined texture or subsurface due to the catastrophic nature of composites result in rejection of components at the last stage of production cycle, and necessitate the minimization of such damages by improving the manufacturing quality in secondary manufacturing process. In this chapter, various fibre orientation (FO) angled GFRP workpieces were milled with different tool rake angles (RA) of end milling cutters. Random experiments were done to test the effects of important milling parameters, such as spindle speed, depth of cut (DOC), FO angle and tool’s RA. The machined wall surface and subsurface were thoroughly analyzed by scanning electron microscope. A reasonable reduction in subsurface damages was observed when using the DOC is low (1 mm) and FO angle of workpiece is less than 90°. At this instance, the machining force and the surface roughness are increased proportionally to a DOC, FO angle of the workpiece and tool RAs, where the surface damages were found to be more. It has also been observed that the damage mechanisms of GFRP composite laminates were dominated by their FO angle.
Chapters in this book
- Frontmatter I
- Preface V
- Contents VII
- About the editors IX
- List of contributors XI
- 1 Mechanical performance of glass- and biofibre-reinforced hybrid composites 1
- 2 Influence of fibre arrangement on mechanical properties of glass fibrereinforced aluminium sandwich laminates 17
- 3 Glass fibre-reinforced composites and their drilling-induced delamination 35
- 4 Drilling of glass fibre-reinforced composites 51
- 5 Influence of milling process parameters on the surface quality of GFRP composites 69
- Index 85
Chapters in this book
- Frontmatter I
- Preface V
- Contents VII
- About the editors IX
- List of contributors XI
- 1 Mechanical performance of glass- and biofibre-reinforced hybrid composites 1
- 2 Influence of fibre arrangement on mechanical properties of glass fibrereinforced aluminium sandwich laminates 17
- 3 Glass fibre-reinforced composites and their drilling-induced delamination 35
- 4 Drilling of glass fibre-reinforced composites 51
- 5 Influence of milling process parameters on the surface quality of GFRP composites 69
- Index 85
