TY - JOUR
T1 - Rotary ultrasonic machining of carbon fiber reinforced plastic composites
T2 - a study on fiber material removal mechanism through single-grain scratching
AU - Ning, Fuda
AU - Wang, Hui
AU - Cong, Weilong
N1 - Publisher Copyright:
© 2019, Springer-Verlag London Ltd., part of Springer Nature.
PY - 2019/7/19
Y1 - 2019/7/19
N2 - Rotary ultrasonic machining (RUM) has become an effective process for both hole making and surface grinding of carbon fiber reinforced plastic (CFRP) composites. Unlike other brittle materials such as ceramic, glass, silicon, etc., CFRP composites exhibit inhomogeneous and anisotropic properties, thereby resulting in different material removal mechanisms. However, the material removal mechanism in RUM of CFRP is still not clearly recognized in the literature. The lack of such knowledge would significantly limit the optimization and practical applications of RUM technique. In this work, single-grain diamond scratching tests without and with ultrasonic vibration are conducted to study the material removal mechanism in RUM of CFRP. Morphology of scratched groove, cross-sectional profiles, and scratching forces are analyzed. The results indicate that CFRP workpiece is extensively removed by the brittle removal mode, causing matrix damage, severe fiber pull-out, and macro-cracks in the conventional scratching test. Whereas, ultrasonic vibration-assisted scratching of CFRP leads to a larger ductile removal region before the successive brittle fractures and cracks. The fiber-matrix debonding and pullout phenomena are also remarkably reduced with only matrix buckling and fiber breakage occurring within the groove. The obtained results will enrich the understanding of the material removal mechanism in RUM of CFRP and contribute to the improvements of part quality during RUM of CFRP.
AB - Rotary ultrasonic machining (RUM) has become an effective process for both hole making and surface grinding of carbon fiber reinforced plastic (CFRP) composites. Unlike other brittle materials such as ceramic, glass, silicon, etc., CFRP composites exhibit inhomogeneous and anisotropic properties, thereby resulting in different material removal mechanisms. However, the material removal mechanism in RUM of CFRP is still not clearly recognized in the literature. The lack of such knowledge would significantly limit the optimization and practical applications of RUM technique. In this work, single-grain diamond scratching tests without and with ultrasonic vibration are conducted to study the material removal mechanism in RUM of CFRP. Morphology of scratched groove, cross-sectional profiles, and scratching forces are analyzed. The results indicate that CFRP workpiece is extensively removed by the brittle removal mode, causing matrix damage, severe fiber pull-out, and macro-cracks in the conventional scratching test. Whereas, ultrasonic vibration-assisted scratching of CFRP leads to a larger ductile removal region before the successive brittle fractures and cracks. The fiber-matrix debonding and pullout phenomena are also remarkably reduced with only matrix buckling and fiber breakage occurring within the groove. The obtained results will enrich the understanding of the material removal mechanism in RUM of CFRP and contribute to the improvements of part quality during RUM of CFRP.
KW - Carbon fiber reinforced plastic composites
KW - Material removal mechanism
KW - Rotary ultrasonic machining
KW - Single-grain scratching
KW - Ultrasonic vibration
UR - http://www.scopus.com/inward/record.url?scp=85068789120&partnerID=8YFLogxK
U2 - 10.1007/s00170-019-03433-7
DO - 10.1007/s00170-019-03433-7
M3 - Article
AN - SCOPUS:85068789120
SN - 0268-3768
VL - 103
SP - 1095
EP - 1104
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
IS - 1-4
ER -