Abstract
Carbon fiber reinforced polymers (CFRP) have got paramount importance in aircraft, aerospace, and other fields due to their attractive properties of high specific strength/stiffness, high corrosion resistance, and low thermal expansion. These materials have also the properties of inhomogeneity, heterogeneity, anisotropy, and low heat dissipation which generate the issues of excessive cutting forces and machining damages (delamination, fiber pull out, matrix burning, etc.). The cutting forces are required to be modeled for their control/ minimization. In this research, a generalized cutting force model has been developed for rotary ultrasonic face milling of CFRP composites. The experimental machining was carried out on CFRP-T700 material. The cutting forces found decreased significantly with the increase of spindle speed while the same found increased with the increase of feed rate and cutting depth. The variation less than 10% has been found between experimental and simulated values (from the model) of cutting forces. However, the higher variation has also observed in the few groups of experiments due to the properties of inhomogeneity, heterogeneity, anisotropy, and low heat dissipation of such materials. The expression for the contact area of the abrasive core tools has been improved and an overlapping cutting allowance has been incorporated the first time. The developed cutting force model has been validated and found robust. So, the generalized cutting force model developed in this paper can be applied to control/minimize the cutting forces for rotary ultrasonic face milling of CFRP composite materials and optimization of the process.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Jones RM (1999) Mechanics of composite materials, 2nd edn. Tylor & Francis Inc., Philadelphia
Kaw AK (2006) Mechanics of composite materials, 2nd edn. Taylor & Francis Group, United Kingdom
Saoubi RM, Axinte D, Soo LS, Nobel C, Attia H, Kappmeyer G, Engin S, Sim W (2015) High performance cutting of advanced aerospace alloys and composite materials. CIRP Ann Manuf Technol 64:577–580
Sheikh-Ahmad JY (2009) Machining of polymer composites. Springer Sci, New York. doi:10.1007/978-0-387-68619-6
Liu DF, Tang YJ, Cong W (2012) A review of mechanical drilling for composite laminates. Compos Struct 94:1265–1279
Kalla D, Sheikh-Ahmad JY, Twomey J (2010) Prediction of cutting forces in helical end milling of fiber reinforced polymers. Int J Mach Tools Manuf 50:882–891
Chen ST, Jiang ZH, Wu YY, Yang HY (2011) Development of a grinding–drilling technique for holing optical grade glass. Int J Mach Tools Manuf 51(2):95–103
Groover MP (2010) Fandamental of modern manufacturing: materials, processes, and systems, 4th edn. John wiley & Sons. Inc, Hoboken
Yuan S, Zhang C, Amin M, Fan H, Liu M (2015) Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling. Int J Adv Manuf Technol. doi:10.1007/s00170-015-7269-x
Xu W, Zhang LC, Wu Y (2014) Elliptic vibration-assisted cutting of fibre-reinforced polymer composites: understanding the material removal mechanisms. J comp sci technol 92:103–111
Pei ZJ, Prabhakar D, Ferreira PM, Haselkorn M (1995) A mechanistic approach to the prediction of material removal rates in rotary ultrasonic machining. J Eng Ind 117(2):142–151
Lau WS, Wang M, Lee WB (1990) Electric discharge machining of carbon fibre composite materials. Int J Mach Tools Manuf 30(2):297–308
Alberadi A, Artaza T, Suarez A, Rivero A, Girot F (2016) An experimental study on abrasive water jet cutting on CFRP/TiA14V stacks for drilling operations. Int J Adv Manuf Technol 86:691–704. doi:10.1007/s00170-015-8192-x
Yuan S, Fan H, Amin M, Zhang C, Guo M (2016) A cutting force prediction dynamic model for side milling of ceramic matrix composites C/SiC based on rotary ultrasonic machining. Int J Adv Manuf Technol 86:37–48. doi:10.1007/s00170-015-8099-6
Ladonne M, Cherif M, Landon Y, Navez JK, Cahuc O, Castelbajac CD (2015) Modelling the vibration-ssisted drilling process: identification of influential phenomena. Int J Adv Manuf Technol 81:1657–1666
Li ZC, Jiao Y, Deines TW, Pei ZJ, Treadwell C (2005) Rotary ultrasonic machining of ceramic matrix composites: feasibility study and designed experiments. Int J Mach Tools Manuf 45:1402–1411
Gong H, Fang FZ, XTH X (2010) Kinematic view of tool life in rotary ultrasonic side milling of hard and brittle materials. Int J Mach Tools Manuf 50(3):303–307
Liu J, Zhang D, Qin L, Yan L (2012) Feasibility study of the rotary ultrasonic elliptical machining of carbon fiber reinforced plastics (CFRP). Int J Mach Tools Manuf 53:141–150
Geng D, Zhang D, Xu Y, He F, Liu D, Duan Z (2015) Rotary ultrasonic elliptical machining for side milling of CFRP: tool performance and surface integrity. Ultrasonics 4(3):157–162 59:128-137
Pei ZJ, Ferreira PM, Haselkorn M (1994) Rotary ultrasonic drilling and milling of ceramics. Paper presented at the Design for Manufacturability and Manufacture of Ceramic Components Symposium, 96 th Ann meet, Am Ceram Soc
Pei ZJ, Ferreira PM (1999) An experimental investigation of rotary ultrasonic face milling. Int J Mach Tools Manuf 39:1327–1344
Feng DJ, Zhao FL, Xu ZG, Guo DM (2006) Mathematic model of material removal rate for ultrasonic milling. China J Mech Eng 17(13):1399–1403
Yuan S, Zhang C, Hu J (2014) Effects of cutting parameters on ductile material removal mode percentage in rotary ultrasonic face machining. Proc Inst Mech Eng B J Eng Manuf 229(9):1547–1556
Zhang CL, Zhang JF, Feng PF (2013) Mathematical model for cutting force in rotary ultrasonic face milling of brittle materials. Int J Adv Manuf Technol 69(1–4):161–170. doi:10.1007/s00170-013-5004-z
Zhang C, Yuan S, Amin M, Fan H, Liu Q (2015) Development of a cutting force prediction model based on brittle fracture for C/SiC in rotary ultrasonic face milling. Int J Adv Manuf Technol. doi:10.1007/s00170-015-7894-x
Marshall DB, Lawn BR, Evans AG (1982) Elastic/plastic indentation damage in ceramics: the lateral crack system. J Am Ceram Soc 65(11):561–566
Lawn BR, Evans AG, Marshall DB (1980) Elastic/plastic indentation damage in ceramics: the median/radial crack system. J Am Ceram Soc 63(9–10):574–581
Collins JA (1981) Failure of materials in mechanical design. Wiley, New York
www. inlandcraft.com/uguides/lapidary_grit_chart.pdf. Accessed 15 September 2016
Author information
Authors and Affiliations
Corresponding author
Electronic supplementary material
(MP4 55,799 kb)
(MP4 45,356 kb)
Rights and permissions
About this article
Cite this article
Amin, M., Yuan, S., Khan, M.Z. et al. Development of a generalized cutting force prediction model for carbon fiber reinforced polymers based on rotary ultrasonic face milling. Int J Adv Manuf Technol 93, 2655–2666 (2017). https://doi.org/10.1007/s00170-017-0469-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0469-9