Abstract
Carbon fiber-reinforced plastics (CFRP) composites are difficult-to-machine materials due to extensive tool wear. This article investigates the impact of carbon fiber types on tool wear in edge-trimming CFRPs, each with the ply angle of 0 deg, 45 deg, 90 deg, or 135 deg, using uncoated tungsten carbide endmills at the high spindle speed of 6000 rpm and the constant feed of 0.0508 mm/rev. Three distinct types of carbon fiber tows, including T300 as standard modulus (SM), IM-7 as intermediate modulus (IM), and K13312 as high modulus (HM), have been vacuum infused into CFRP laminates and edge trimmed to investigate wear characteristics. Three wear criteria measured are flank wear, edge rounding radii, and worn area. The results show that tool wear is influenced by carbon fiber properties, such as fiber tensile strength, tensile modulus, and fiber microstructure. Overall, IM carbon fibers with the highest tensile strength produced the most extensive tool wear due to the abrasive carbon fibers. Of four fiber directions, the largest tool wear was obtained from the 45 deg angle, while the lowest tool wear occurred in the 0 deg angle.
References
1.
Cunningham
, C. R.
, Shokrani
, A.
, and Dhokia
, V.
, 2018
, “Edge Trimming of Carbon Fibre Reinforced Plastic
,” Procedia CIRP
, 77
, pp. 199
–202
. 2.
Geier
, N.
, Davim
, J. P.
, and Szalay
, T.
, 2019
, “Advanced Cutting Tools and Technologies for Drilling Carbon Fibre Reinforced Polymer (CFRP) Composites: A Review
,” Composites, Part A
, 125
, p. UNSP 105552
. 3.
Li
, C.
, Mi
, S.
, An
, Q.
, Chen
, M.
, and Xu
, J.
, 2018
, “Study of Drilling-Induced Defects for CFRP Composites Using New Criteria
,” Compos. Struct.
, 201
, pp. 1076
–1087
. 4.
Chandramohan
, D.
, and Murali
, B.
, 2014
, “Machining of Composites—A Review
,” Acad. J. Manuf. Eng.
, 12
(3
), pp. 67
–71
.5.
Eneyew
, E. D.
, and Ramulu
, M.
, 2014
, “Experimental Study of Surface Quality and Damage When Drilling Unidirectional CFRP Composites
,” J. Mater. Res. Technol.
, 3
(4
), pp. 354
–362
. 6.
Faraz
, A.
, Biermann
, D.
, and Weinert
, K.
, 2009
, “Cutting Edge Rounding: An Innovative Tool Wear Criterion in Drilling CFRP Composite Laminates
,” Int. J. Mach. Tools Manuf.
, 49
(15
), pp. 1185
–1196
. 7.
Wang
, X.
, Kwon
, P. Y.
, Sturtvant
, C.
, Kim
, D.
, and Lantrip
, J.
, 2013
, “Tool Wear of Coated Drills in Drilling CFRP
,” J. Manuf. Processes
, 15
(1
), pp. 127
–135
. 8.
Rawat
, S.
, and Attia
, H.
, 2009
, “Wear Mechanisms and Tool Life Management of WC–Co Drills During Dry High Speed Drilling of Woven Carbon Fibre Composites
,” Wear
, 267
(5–8
), pp. 1022
–1030
. 9.
Henerichs
, M.
, Voß
, R.
, Kuster
, F.
, and Wegener
, K.
, 2015
, “Machining of Carbon Fiber Reinforced Plastics: Influence of Tool Geometry and Fiber Orientation on the Machining Forces
,” CIRP J. Manuf. Sci. Technol.
, 9
, pp. 136
–145
. 10.
Muhamad Khairussaleh
, N. K.
, Che Haron
, C. H.
, and Ghani
, J. A.
, 2016
, “Study on Wear Mechanism of Solid Carbide Cutting Tool in Milling CFRP
,” J. Mater. Res.
, 31
(13
), pp. 1893
–1899
. 11.
Hagino
, M.
, and Inoue
, T.
, 2013
, “Effect of Carbon Fiber Orientation and Helix Angle on CFRP Cutting Characteristics by End-Milling
,” Int. J. Autom. Technol.
, 7
(3
), pp. 292
–299
. 12.
Nguyen
, D.
, Bin Abdullah
, M. S.
, Khawarizmi
, R.
, Kim
, D.
, and Kwon
, P.
, 2020
, “The Effect of Fiber Orientation on Tool Wear in Edge-Trimming of Carbon Fiber Reinforced Plastics (CFRP) Laminates
,” Wear
, 450–451
, p. 203213
. 13.
Merino-Pérez
, J. L.
, Royer
, R.
, Merson
, E.
, Lockwood
, A.
, Ayvar-Soberanis
, S.
, and Marshall
, M. B.
, 2016
, “Influence of Workpiece Constituents and Cutting Speed on the Cutting Forces Developed in the Conventional Drilling of CFRP Composites
,” Compos. Struct.
, 140
, pp. 621
–629
. 14.
Merino-Pérez
, J. L.
, Royer
, R.
, Ayvar-Soberanis
, S.
, Merson
, E.
, and Hodzic
, A.
, 2015
, “On the Temperatures Developed in CFRP Drilling Using Uncoated WC-Co Tools Part I: Workpiece Constituents, Cutting Speed and Heat Dissipation
,” Compos. Struct.
, 123
, pp. 161
–168
. 15.
Merino-Pérez
, J. L.
, Royer
, R.
, Ayvar-Soberanis
, S.
, Merson
, E.
, and Hodzic
, A.
, 2015
, “Induced Thermo-Mechanical Damage in the Drilling of Thermoplastic-Toughened CFRP Composites
,” Proceedings of 20th International Conference on Composite Materials
, Copenhagen, Denmark
, July 19–24
, p. 12
.16.
Pérez
, J. L. M.
, Merson
, E.
, Soberanis
, S. A.
, and Hodzic
, A.
, 2014
, “The Applicability of Taylor’s Model to the Drilling of CFRP Using Uncoated WC-Co Tools: The Influence of Cutting Speed on Tool Wear
,” Int. J. Mach. Mach. Mater.
, 16
(2
), p. 95
. 17.
Feito
, N.
, Diaz-Álvarez
, A.
, Cantero
, J. L.
, Rodríguez- Millán
, M.
, and Miguélez
, H.
, 2016
, “Experimental Analysis of Special Tool Geometries When Drilling Woven and Multidirectional CFRPs
,” J. Reinf. Plast. Compos.
, 35
(1
), pp. 33
–55
. 18.
Xu
, J.
, An
, Q.
, Cai
, X.
, and Chen
, M.
, 2013
, “Drilling Machinability Evaluation on New Developed High-Strength T800S/250F CFRP Laminates
,” Int. J. Precis. Eng. Manuf.
, 14
(10
), pp. 1687
–1696
. 19.
Chen
, W.-C.
, 1997
, “Some Experimental Investigations in the Drilling of Carbon Fiber-Reinforced Plastic (CFRP) Composite Laminates
,” Int. J. Mach. Tools Manuf.
, 37
(8
), pp. 1097
–1108
. 20.
Chand
, S.
, 2000
, “Review Carbon Fibers for Composites
,” J. Mater. Sci.
, 35
(6
), pp. 1303
–1313
. 21.
Huson
, M. G.
, 2017
, “3—High-Performance Pitch-Based Carbon Fibers,” Structure and Properties of High-Performance Fibers
, G.
Bhat
, ed., Woodhead Publishing
, Oxford
, pp. 31
–78
.22.
Morgan
, P.
, 2005
, Carbon Fibers and Their Composites
, Taylor & Francis
, London
.23.
Naslain
, R.
, 2000
, “Carbon Fibers From Pan and Pitch,” Advanced Inorganic Fibers: Process—Structure—Properties—Applications
, F. T.
Wallenberger
, R.
Naslain
, J. B.
Macchesney
, H. D.
Ackler
, and F. T.
Wallenberger
, eds., Springer US
, Boston, MA
, pp. 233
–264
.24.
Inagaki
, M.
, 2000
, “CHAPTER 4—Carbon Fibers,” New Carbons—Control of Structure and Functions
, M.
Inagaki
, ed., Elsevier Science
, Oxford
, pp. 82
–123
.25.
Swan
, S.
, Yuksel
, T.
, Kim
, D.
, and Gurocak
, H.
, 2017
, “Automation of the Vacuum Assisted Resin Transfer Molding Process for Recreational Composite Yachts
,” Polym. Compos.
, 38
(11
), pp. 2411
–2424
. 26.
Kim
, S.-Y.
, Shim
, C. S.
, Sturtevant
, C.
, Kim
, D.
, and Song
, H. C.
, 2014
, “Mechanical Properties and Production Quality of Hand-Layup and Vacuum Infusion Processed Hybrid Composite Materials for GFRP Marine Structures
,” Int. J. Nav. Archit. Ocean Eng.
, 6
(3
), pp. 723
–736
. 27.
Hammami
, A.
, and Gebart
, B. R.
, 2000
, “Analysis of the Vacuum Infusion Molding Process
,” Polym. Compos.
, 21
(1
), pp. 28
–40
. 28.
Ahmad
, J.
, 2009
, “Introduction to Polymer Composites,” Machining of Polymer Composites
, J
Ahmad
, ed., Springer US
, Boston, MA
, pp. 1
–35
.29.
Toray Composite America Inc.
, 2018
, “T300 Data Set
,” T300 Rev. 6 Technical Datasheet.30.
Hexcel Corporation
, 2020
, “IM7 HexTow DataSheet
,” CTA 351 NV20 Datasheet.31.
Mitsubishi Rayon Co., Ltd.
, 2016
, “Coal Tar Pitched Based Carbon Fiber DIALEAD—Datasheet
,” Technical Datasheet for Material Selection.32.
Zitoune
, R.
, Krishnaraj
, V.
, Sofiane Almabouacif
, B.
, Collombet
, F.
, Sima
, M.
, and Jolin
, A.
, 2012
, “Influence of Machining Parameters and New Nano-Coated Tool on Drilling Performance of CFRP/Aluminium Sandwich
,” Composites, Part B
, 43
(3
), pp. 1480
–1488
. 33.
Swan
, S.
, Bin Abdullah
, M. S.
, Kim
, D.
, Nguyen
, D.
, and Kwon
, P.
, 2018
, “Tool Wear of Advanced Coated Tools in Drilling of CFRP
,” ASME J. Manuf. Sci. Eng.
, 140
(11
), pp. 111018
–111018–10
. 34.
Nguyen
, D.
, Voznyuk
, V.
, Bin Abdullah
, M. S.
, Kim
, D.
, and Kwon
, P. Y.
, 2019
, “Tool Wear of Superhard Ceramic Coated Tools in Drilling of CFRP/Ti Stacks
,” Conference Proceedings of MSEC 2019
, Erie, PA
, June 10–14
.35.
Lasdon
, L. S.
, Waren
, A. D.
, Jain
, A.
, and Ratner
, M.
, 1978
, “Design and Testing of a Generalized Reduced Gradient Code for Nonlinear Programming
,” ACM Trans. Math. Softw.
, 4
(1
), pp. 34
–50
. 36.
Kwon
, P.
, and Kountanya
, R.
, 1999
, “Experimental Observations on Flank Wear in Machining Spherodized Plain Carbon Steels
,” Tribol. Trans.
, 42
(2
), pp. 265
–272
. 37.
Flöck
, J.
, Friedrich
, K.
, and Yuan
, Q.
, 1999
, “On the Friction and Wear Behaviour of PAN- and Pitch-Carbon Fiber Reinforced PEEK Composites
,” Wear
, 225–229
(Part 1), pp. 304
–311
. 38.
Ramulu
, M.
, Kim
, D.
, and Choi
, G.
, 2003
, “Frequency Analysis and Characterization in Orthogonal Cutting of Glass Fiber Reinforced Composites
,” Composites, Part A
, 34
(10
), pp. 949
–962
. 39.
Attia
, H.
, Sadek
, A.
, and Meshreki
, M.
, 2012
, “High Speed Machining Processes for Fiber-Reinforced Composites,” Machining Technology for Composite Materials: Principles and Practice
, H.
Hocheng
, ed., Woodhead Publishing
, pp. 333
–364
.40.
Sheikh-Ahmad
, J.
, and Davim
, J. P.
, 2012
, “5—Tool Wear in Machining Processes for Composites,” Machining Technology for Composite Materials: Principles and Practice
,, H.
Hocheng
, ed., Woodhead Publishing
, pp. 116
–153
.41.
Xie
, Y.
, Lu
, L.
, Hou
, Z.
, Tang
, Y.
, Miao
, L.
, and Liu
, X.
, 2016
, “Fracture Behavior of PAN-Based Carbon Fiber Tow in a Chopping Process on an Elastic Support
,” Fibers Polym.
, 17
(8
), pp. 1262
–1268
. Copyright © 2021 by ASME
You do not currently have access to this content.
