Performance of a new hybrid cutting-abrasive tool for the machining of fibre reinforced polymer composites
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ORIGINAL ARTICLE
Performance of a new hybrid cutting-abrasive tool for the machining of fibre reinforced polymer composites Islam Shyha 1,2
&
Dehong Huo 3 & Peyman Hesamikojidi 3 & Hossam Eldessouky 4 & Mahmoud Ahmed El-Sayed 4
Received: 18 June 2020 / Accepted: 7 December 2020 # The Author(s) 2020
Abstract A new hybrid cutting-abrasive machining tool (turn-grind) is detailed for high-quality machining of fibre reinforced polymer (FRP) composites, comprising single point carbide inserts electroplated with multi-layers of diamond abrasives 120 μm grain size, to form an abrasive region adjacent to an abrasive-free cutting edge. Experimental data are presented for turning tubes of CFRP and GFRP. The surface quality of workpieces after machining was evaluated through surface roughness measurements and SEM imaging. Cutting-only caused more defects such as delamination and fibre to pull out. Compared with cutting-only, contact and non-contact measurement of surface roughness (Ra) in both axial and radial directions showed an increase for CFRP and GFRP with roundness error reduced to 50%. No significant increase in cutting force was observed. Keywords CFRP . GFRP . Composite machining . Hybrid machining . Abrasive machining
1 Introduction The use of composite materials is rapidly increasing due to their superior mechanical properties, in particular, the strength to weight ratio. Typically, a single machining process is applied to achieve the required dimensional accuracy and geometrical requirement of composite components. Previous research was widely conducted to understand machining characteristics of different types of composite materials either experimentally [1, 2] or numerically [3–5]. However, with the emergence of carbon and glass fibre reinforced polymers (CFRP and GFRP) as possible alternatives for metals, industries such as aerospace and automotive have set stringent
* Islam Shyha [email protected] 1
Mechanical and Construction Engineering Department, Northumbria University at Newcastle, Newcastle upon Tyne NE1 8ST, UK
2
School of Engineering and the Built Environment, Edinburgh Napier University, Edinburgh EH10 5DT, UK
3
Mechanical Engineering, School of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UK
4
Department of Industrial and Management Engineering, Arab Academy for Science and Technology and Maritime Transport, Abu Qir, PO Box 1029, Alexandria 21599, Egypt
requirements on surface integrity and accuracy of machined parts. Hybrid machining has the potential to fulfil these requirements. Hybrid manufacturing processes are based on the simultaneous and controlled interaction of process mechanisms and energy sources/tools. Lauwers et al. [6] have reported the significant effect when hybrid processes are used on the process performance due to the combined actions of the processes which result in higher machinability, reduction in processes forces and tool wear. Hybrid processes exploit the advantages of one process and overcome the limitation of others. Hybrid processes ca
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