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Down Milling Trimming Process Optimization for Carbon Fiber-Reinforced Plastic

:	Saiful Bahri Mohamed, Radzuwan Ab Rashid, Martini Muhamad, Jailani Ismail
:	Down Milling Trimming Process Optimization for Carbon Fiber-Reinforced Plastic
:	Springer-Verlag
:	9789811318047
:	1
:	CHF 47.50
:

:	Maschinenbau, Fertigungstechnik
:	English

:	76
:	Wasserzeichen/DRM
:	PC/MAC/eReader/Tablet
:	PDF

This book offers recommendations on the milling processes for the carbon fiber reinforced plastic CFRP/Al2024. Due to the anisotropic and non-homogeneous structure of CFRP and the ductile nature of aluminum, the machining of this material is very challenging and causes various types of damage, such as matrix cracking and thermal alterations, fiber pullout and fuzzing during drilling and trimming, which affect the quality of machined surface.

The book studies and models the machined surface quality of CFRP/Al2024 using a two-level full factorial design experiment. It describes the processes of trimming using down milling, and statistically and graphically analyzes the influence and interaction of cutting parameters. Lastly, the book presents the optimization of the cutting parameters in order to create a surface texture quality of CFRP/Al2024 to less than 1 µm.

	Preface	6
	Contents	8
	1 Composite Materials and Types of Machining	10
	1.1 Defining Composite Material	10
	1.2 CFRP Composite Laminates	11
	1.3 Fiber Metal Laminate (FML)	11
	1.4 Classification of Composite Machining	12
	1.4.1 Drilling	13
	1.4.2 Turning	14
	1.4.3 Milling	14
	1.4.4 Trimming	16
	1.4.5 Grinding	18
	1.5 Laser Machining	19
	1.5.1 Abrasive Water Jet Machining	19
	1.5.2 Electrical Discharge Machining	20
	References	21
	2 Cutting Parameters and the Machinability Performance	24
	2.1 Types of Cutting Parameters	24
	2.1.1 Cutting Speed (m/min)	24
	2.1.2 Spindle Speed (RPM)	25
	2.1.3 Feed Rates (mm/min)	25
	2.1.4 Depth of Cut (DOC)	27
	2.2 Surface Roughness	27
	2.3 Machined Surface Quality of Composites	28
	2.4 Design of Experiments (DoE)	29
	2.4.1 Two-Level Factorial Designs	30
	2.4.2 The 23 Factorial Design	31
	2.5 Research on Machining of Fiber Metal Laminates	32
	References	34
	3 The Carbon Fiber-Reinforced Plastic Project	37
	3.1 Overview of the Project	37
	3.1.1 The Experimentation	37
	3.1.2 Workpiece Details	37
	3.1.3 Solid Carbide End Mill Cutting Tool	38
	3.1.4 Machine Setup	40
	3.1.5 Control Parameters and Experimental Design Layout	42
	3.1.6 Edge Trimming Parameters	43
	3.1.7 Edge Trimming Process	43
	3.1.8 Collecting Data of Surface Roughness	43
	3.1.9 DoE Approach	45
	3.1.10 Design of Experiment Software	47
	3.1.11 Augment Design	51
	3.1.12 Validation of Experiments	52
	3.1.13 Summary of DoE Approach	54
	References	56
	4 Learning from the Carbon Fiber-Reinforced Plastic Project	57
	4.1 Surface Roughness (Ra) of CFRP and Al2024	57
	4.2 Analysis of Variance of CFRP and Al2024 Response	57
	4.3 Final Equation in Terms of Actual Factors for CFRP and Al2024 Responses	60
	4.4 The Form of Interaction in a 3D Graph of CFRP Response	63
	4.5 The Form of Interaction in a 3D Graph of Al2024 Response	64
	4.6 Edge Trimming Parameter Optimization	65
	4.6.1 Numerical Optimization	65
	4.6.2 Graphical Optimization	68
	4.7 Conclusion and Recommendations for Future Works	69
	Reference	69
	Appendix A	70
	Appendix B	72
	Appendix C	75
	High-Performance Solid Carbide End Mills • CFRP Router	75