Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites
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ORIGINAL ARTICLE
Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites Norbert Geier 1 Received: 15 May 2020 / Accepted: 24 September 2020 / Published online: 6 October 2020 # The Author(s) 2020
Abstract Machining of carbon fibre reinforced polymer (CFRP) composites is extremely difficult, mainly due to their inhomogeneous and anisotropic properties. Predicting of cutting force during machining of CFRP is also difficult because the machinability properties of the composite are significantly orientation-dependent (fibre and machining directions). The main objective of the present study is to analyse the influence of fibre orientation on cutting force in milling of unidirectional CFRP. Up and down milling experiences were conducted based on a full factorial design. Experimental data were processed by fast Fourier transformation, regression analysis, and graphical adequate analysis. Multiple-order polynomial models were developed in order to minimise cutting force. Experimental results show that fibre orientation angle significantly influences the cutting force; furthermore, it does not have a significant effect on the passive force component, while the radial force component is more sensitive to the fibre orientation at up milling, than at down milling. An optimal condition is recommended for zig-zag milling of unidirectional CFRPs. Keywords CFRP . Machining . Cutting force . Fibre orientation . Milling
Nomenclature F (N) Ff (N) Fp (N) Fr (N) k (1) n (rpm) s (act.) vc (m/min) vf (mm/min) α (°) γ (°) δ (°) θ (°) ϕ (°) CFRP deg
Cutting force Feed cutting force component Passive cutting force component Radial cutting force component Direction of fibres Spindle speed Empirical standard deviation Cutting speed Feed rate Clearance angle Rake angle Interpretability interval Fibre cutting angle Fibre orientation angle Carbon fibre reinforced polymer Degree of the polynomial model
* Norbert Geier [email protected] 1
Faculty of Mechanical Engineering, Department of Manufacturing Science and Engineering, Budapest University of Technology and Economics, Budapest, Hungary
E ME UD
Expected value Main effect Unidirectional
1 Introduction Carbon fibre–reinforced polymer (CFRP) composite materials are favoured due to their excellent specific mechanical properties in industries where low weight and high strength are required [1, 2]. For example, almost 50% of the structural elements of the Boeing 787 airliner consist of composite materials [3]. By using the novel composites, engineers were able to achieve 20% weight loss and 35% maintenance time reduction over previous models (Boeing 767 and 777). In the aerospace industry, as well as in the automotive, wind turbine, military, sports, and aerospace industries, manufacturers strive to laminate CFRP components in a single operation (moulding and hardening); however, they often require further processing before they can be used or assembled [4–6]. These may include (i) removing material build-up in the dividing plane of the laminating tool,
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