An investigation of the effect of tool approaching angle in turning of CFRP composite materials
-
Zülküf Demir
Abstract
Carbon Fibers Reinforced Plastics (CFRP) composite material bars were machined on the lathe. In experiments −15°, 0°, 15°, 30°, and 45° approach angles, 0.1 mm × rev-1, 0.15 mm × rev-1, and 0.2 mm × rev-1 feed rates and 560 rpm, 800 rpm, and 1120 rpm spindle speeds were selected. At −15° and 0° approach angles, the deformation influence was dominant on surface roughness and chip morphology, while the cutting effect taking place at the cutting edge was dominant at 30° and 45° approach angles. Primarily at 45°, the most significant roughness values and the shortest cut fibers were achieved due to the occurrence of maximum shear stress according to Tresca. However, fibers were removed from samples on the whole form as bundles, without any cutting, at −15° and 0° approach angles, by the effect of deformation. According to ANOVA, regression and variance analysis results were obtained with p-values and probability results of surface roughness smaller than 0.05 and 5 %, respectively. These results showed that the feed rate was the most influential parameter for turning of CFRP material, followed by the approach angle and spindle speed, respectively. However, the least influential parameter in the processes was spindle speed.
References
1 E.Brinksmeier, S.Fangmann, R.Rentsch: Drilling of composites and resulting surface integrity, CIRP Annals-Manufacturing Technology60 (2011), No. 1, pp. 57–6010.1016/j.cirp.2011.03.077Search in Google Scholar
2 S. T.Kumaran, T. J.Ko, C.Li, Z.Yu, M.Uthayakumar: Rotary ultrasonic machining of woven CFRP composite in a cryogenic environment, Journal of Alloys and Compounds698 (2017), pp. 984–99310.1016/j.jallcom.2016.12.275Search in Google Scholar
3 R.Zemman, L.Kain, F.Bleicher: Vibration assisted machining of carbon fiber reinforced polymers, B. Katalinic (Eds): Procedia Engineering, 24th DAAAM International Symposium on Intelligent Manufacturing and Automation,Vol. 69, (2014), pp. 536–54310.1016/j.proeng.2014.03.023Search in Google Scholar
4 C. R.Dandekar, Y. C.Shin: Modeling of machining of composite materials: A review, International Journal of Machine Tools & Manufacture57 (2012), pp. 102–12110.1016/j.ijmachtools.2012.01.006Search in Google Scholar
5 A.Salama, Y.Yan, L.Li, P.Mativenga, D.Whitehead, A.Sabli: Understanding the self-limiting effect in picosecond laser single and multiple parallel pass drilling/machining of CFRP composite and mild steel, Materials & Design107 (2016), pp. 461–46910.1016/j.mathdes.2016.06.048Search in Google Scholar
6 C. C.Tsao: Experimental study of drilling composite materials with step-core drill, Materials & Design29 (2008), pp. 740–174410.1016/j.matdes.2008.03.022Search in Google Scholar
7 V.Lopresto, A.Caggiano, R.Teti: High performance cutting of fiber reinforced plastic composite materials, R. Wertheim, S. Ihlefeldt, C. Hochmuth, M. Putz (Eds): Procedia CIRP 7th HPC-CIRP Conference on High Performance Cutting46 (2016), pp. 71–8210.1016/j.procir.2016.05.079Search in Google Scholar
8 N. R.Mathivanan, B. S.Mahesh, H. A.Shetty: An experimental investigation on the process parameters influencing machining forces during milling of carbon and glass fiber laminates, Measurement91 (2016), pp. 39–4510.1016/j.measurement.2016.04.077Search in Google Scholar
9 S.Zenia, L. B.Ayed, M.Nouari, A.Delameziere: An elastoplastic constitutive damage model to simulate the chip formation process and workpiece subsurface defects when machining CFRP composites, V. Shulze (Ed.): Procedia CIRP 15th CIRP Conference on Modelling of Machining Operations31 (2015), pp. 100–105Search in Google Scholar
10 K.Kahwash, I.Shyha, A.Maheri: Machining unidirectional composites using single-point tools: analysis of cutting forces, chip formation and surface integrity, J. M. Canela (Ed.): Procedia Engineering, The Manufacturing Engineering Society International Conference MESIC 2015132 (2015), pp. 569–576Search in Google Scholar
11 G.Kathirvel: High speed turning of carbon fiber-epoxy composite material, N. C. Sarada (Ed.): Proceedings of the 8th International Conference on Science, Engineering and Technology (SET), VIT, Vellore, Tamil Nadu, India (2014), pp. 50–53Search in Google Scholar
12 A.Yardimeden, E.Kilickap, Y. H.Celik: Effect of cutting parameters and point angle on thrust force and delamination in drilling of CFRP, Materials Testing56 (2014), No. 11-12, pp. 1042–10480.3139/120.110666Search in Google Scholar
13 N.Duboust, D.Melis, C.Pinna, H.Ghadbeigi, A.Collis, S.Ayvar-Soberanis, K.Kerrigan: Machining of carbon fiber: optical surface damage characterisation and tool wear study, M. A. Davies, et al. (Eds): Procedia CIRP 3rd CIRP Conference on Surface Integrity (CIRP CSI)45 (2016), pp. 71–74Search in Google Scholar
14 A. K.Parida, B. C.Routara, R. K.Bhuyan: Surface roughness model and parametric optimization in machining of GFRP composite: Taguchi and Response surface methodology approach, S. K. Singh (Ed.): Materials Today: Proceedings 4th International Conference on Materials Processing and Characterization,Vol. 2, (2015), pp. 3065–3074Search in Google Scholar
15 A. K.Parida, R.Das, A. K.Sahoo, B. C.Routara: Optimization of cutting parameters for surface roughness in machining of GFRP composite with graphite/fly ash filler, S. K.Singh (Ed.): Procedia Materials Science of 3rd International Conference on Materials Processing and Characterisation (IMPC 2014), Vol. 6, Hyderabad, India (2014), pp. 1533–1538Search in Google Scholar
16 J. S.Pang, M. N. M.Ansari, O. S.Zaroog, M. H.Ali, S. M.Sapuan: Taguchi design optimization of machining parameters on the CNC end milling process of halloysitte nanotube with aluminium reinforced epoxy matrix (HNT/Al/Ep) hybrid composite, HBRC Journal10 (2014), pp. 138–14410.1016/j.hbrcj.2013.09.007Search in Google Scholar
17 U. H.Khashaba, I. A.El-Sonbaty, A. I.Selmy, A. A.Megahed: Machinability analysis in drilling woven GFR/epoxy composites: Part I – Effect of machining parameters, Composites Part A41 (2010), pp. 391–40010.1016/j.compositesa.2009.11.006Search in Google Scholar
18 S. A.Hussain, V.Pandurangadu, K. P.Kumar, V. V.Bharathi: A predictive model for surface roughness in turning glass fiber reinforced plastics by carbide tool (K-20) using soft computing, Jordan Journal of Mechanical Industrial Engineering5 (2011), pp. 433–438Search in Google Scholar
19 V.Madhavan, G.Lipczynski, B.Lane, E.Whitenton: Fiber orientation angle effect in machining of unidirectional CFRP laminated composites, Journal of Manufacturing Process20 (2015), pp. 431–44210.1016/j.jmapro.2014.06.001Search in Google Scholar
20 E.Uhlmann, F.Sammler, S.Richarz, G.Reucher, R.Hufschmied, A.Frank, B.Stawiszynski, F.Protz: Machining of carbon and glass fiber reinforced composites, R. Wertheim, S. Ilefeldt, C. Hochmut, M. Putz (Eds): Procedia CIRP 7th HPC 2016-CIRP Conference on High Performance Cutting46 (2016), pp. 63–66Search in Google Scholar
21 E.Kilickap: Determination of optimum parameters on delamination in drilling of GFRP composites by Taguchi method, Indian Journal of Engineering Materials and Science17 (2010), pp. 265–274Search in Google Scholar
22 M.Saleem, L.Toubal, R.Zitoune, H.Bougherara: Investigation the effect of machining processes on the mechanical behaviour of composite plates with circular holes, Composites Part A55 (2013), pp. 169–17710.1016/j.compositesa.2013.09.002Search in Google Scholar
23 K. A.Calzada, S. G.Kapoor, R. E.DeVor, J.Samuel, A. K.Srivastava: Modeling and interpretation of fiber orientation-based failure mechanism in machining of carbon fiber-reinforced polymer composites, Journal of Manufacturing Process14 (2012), pp. 141–14910.1016/j.jmapro.2011.09.005Search in Google Scholar
24 G. V. G.Rao, P.Mahajan, N.Bhatnagar: Machining of UD-GFRP composites chip formation mechanism, Composite Science and Technology67 (2007), pp. 2271–228110.1016/j.compscitech.2007.01.025Search in Google Scholar
25 M.Kronenberg: Machining science and application, theory and practice for operation and development of machining processes, 1st Ed., Pergamon Press, UK (1966)Search in Google Scholar
© 2019, Carl Hanser Verlag, München
Articles in the same Issue
- Inhalt/Contents
- Contents
- Fachbeiträge/Technical Contributions
- Non-destructive testing derived parameters for microstructure-based residual service life assessment of aging metallic materials in nuclear engineering
- Influence of cryogenic treatment on the corrosion of AZ91 and AM60 magnesium alloys in an isotonic solution
- A test method for the determination of the cyclic material properties of electrical steel strip under strain-controlled loading
- Development of a laser-based line scan measurement system for the surface characterization of reinforcing steel
- Inclusion and microstructure characteristics in steel with TiO2 nanoparticle additions
- Mechanical test procedures for the evaluation of hydrogen-assisted damage in high-strength steel
- Effects of particle reinforcement on the bending and compressive behaviors of composite pipes
- Effects of process parameters on the mechanical properties of dissimilar thin Al welds
- Effect of hard chrome plating parameters on the wear resistance of low carbon steel
- The use of color etching to study the microstructure of laser welded steel used in the automotive industry
- Mechanical properties of plain woven kenaf/glass fiber reinforced polypropylene hybrid composites
- Optimization of cryogenic treatment effects on the surface roughness of cutting tools
- Effects of ball burnishing on the surface quality of Al 7075 alloy
- An investigation of the effect of tool approaching angle in turning of CFRP composite materials
Articles in the same Issue
- Inhalt/Contents
- Contents
- Fachbeiträge/Technical Contributions
- Non-destructive testing derived parameters for microstructure-based residual service life assessment of aging metallic materials in nuclear engineering
- Influence of cryogenic treatment on the corrosion of AZ91 and AM60 magnesium alloys in an isotonic solution
- A test method for the determination of the cyclic material properties of electrical steel strip under strain-controlled loading
- Development of a laser-based line scan measurement system for the surface characterization of reinforcing steel
- Inclusion and microstructure characteristics in steel with TiO2 nanoparticle additions
- Mechanical test procedures for the evaluation of hydrogen-assisted damage in high-strength steel
- Effects of particle reinforcement on the bending and compressive behaviors of composite pipes
- Effects of process parameters on the mechanical properties of dissimilar thin Al welds
- Effect of hard chrome plating parameters on the wear resistance of low carbon steel
- The use of color etching to study the microstructure of laser welded steel used in the automotive industry
- Mechanical properties of plain woven kenaf/glass fiber reinforced polypropylene hybrid composites
- Optimization of cryogenic treatment effects on the surface roughness of cutting tools
- Effects of ball burnishing on the surface quality of Al 7075 alloy
- An investigation of the effect of tool approaching angle in turning of CFRP composite materials