TY - JOUR
T1 - A study on the effects of machining variables in surface grinding of CFRP composites using rotary ultrasonic machining
AU - Wang, Hui
AU - Cong, Weilong
AU - Ning, Fuda
AU - Hu, Yingbin
N1 - Publisher Copyright:
© 2017, Springer-Verlag London Ltd., part of Springer Nature.
Copyright:
Copyright 2018 Elsevier B.V., All rights reserved.
PY - 2018/4/1
Y1 - 2018/4/1
N2 - Due to their excellent properties, carbon fiber-reinforced plastic (CFRP) composites are attractive in many industries, including aerospace, automobile, sports, etc. The structure of anisotropy and heterogeneity and the high abrasive resistance of carbon fibers make CFRPs difficult to cut in surface grinding processes. Many problems, including high cutting force, high tool wear, severe delamination, and high cutting temperature, are associated with conventional surface grinding processes. To reduce or eliminate these problems, surface grinding of CFRP composites using rotary ultrasonic machining (RUM) has been conducted. Machining variables play dominant roles in such a process. However, no investigations on effects of machining variables on output variables were reported. This paper, for the first time, reports effects of machining variables (ultrasonic power, tool rotation speed, feed rate, and depth of cut) on output variables (cutting force, torque, and surface roughness). The results revealed that the cutting force could be decreased by using higher level of ultrasonic power, higher level of tool rotation speed, lower level of feed rate, or lower level of depth of cut. Lower surface roughness could be achieved by a decrease of ultrasonic power, an increase of tool rotation speed, a decrease of feed rate, or a decrease of depth of cut. The machined CFRP surfaces’ morphology and the characteristics of damaged carbon fibers were, for the first time, analyzed and reported in such a process.
AB - Due to their excellent properties, carbon fiber-reinforced plastic (CFRP) composites are attractive in many industries, including aerospace, automobile, sports, etc. The structure of anisotropy and heterogeneity and the high abrasive resistance of carbon fibers make CFRPs difficult to cut in surface grinding processes. Many problems, including high cutting force, high tool wear, severe delamination, and high cutting temperature, are associated with conventional surface grinding processes. To reduce or eliminate these problems, surface grinding of CFRP composites using rotary ultrasonic machining (RUM) has been conducted. Machining variables play dominant roles in such a process. However, no investigations on effects of machining variables on output variables were reported. This paper, for the first time, reports effects of machining variables (ultrasonic power, tool rotation speed, feed rate, and depth of cut) on output variables (cutting force, torque, and surface roughness). The results revealed that the cutting force could be decreased by using higher level of ultrasonic power, higher level of tool rotation speed, lower level of feed rate, or lower level of depth of cut. Lower surface roughness could be achieved by a decrease of ultrasonic power, an increase of tool rotation speed, a decrease of feed rate, or a decrease of depth of cut. The machined CFRP surfaces’ morphology and the characteristics of damaged carbon fibers were, for the first time, analyzed and reported in such a process.
KW - CFRP composite
KW - Machining variables
KW - Morphology characteristics
KW - Rotary ultrasonic machining
KW - Surface grinding
UR - http://www.scopus.com/inward/record.url?scp=85038098164&partnerID=8YFLogxK
U2 - 10.1007/s00170-017-1468-6
DO - 10.1007/s00170-017-1468-6
M3 - Article
AN - SCOPUS:85038098164
VL - 95
SP - 3651
EP - 3663
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
SN - 0268-3768
IS - 9-12
ER -