Thesis
Effects of fiber orientations and properties on tool wear and machined surface quality in machining of carbon fiber reinforced plastics laminate
Washington State University
Master of Science (MS), Washington State University
05/2019
DOI:
https://doi.org/10.7273/000004004
Handle:
https://hdl.handle.net/2376/118597
Abstract
The application of carbon fiber reinforced plastics (CFRP) is significantly increasing due to their excellent mechanical properties, and increased flexibility in design. Tool wear is a severe problem in CFRP machining processes, i.e., trimming and drilling. The understanding of tool wear, regarding the influence of fiber orientation and properties in machining of CFRP, is still lacking. In this investigation, both the effects of fiber orientations and properties on tool wear in the machining of CFRP are systematically studied through edge trimming of CFRP. The effects of tool wear on CFRP hole quality have been evaluated in drilling of CFRP. The wear mechanisms and CFRP surface characteristics in edge trimming of 0°, 45°, 90°, and 135° fibers are discussed based on wear microstructure, chip formation evidence, surface damage and the contours of worn tools. Additionally, the tool wear dependency on carbon fiber properties is investigated through edge trimming of an intermediate modulus fiber (IM-7) based CFRP, and a high modulus fiber (K13312) based CFRP. In the CFRP drilling experiment, the inaccuracies and damages in CFRP holes, caused due to tool wear, have been assessed through a comparative study of three carbide drills, uncoated, BAM coated, and (AlCrSi/Ti)N coated drill. The results show that 45° fibers create the largest flank wear, 90° fibers create both the largest edge rounding and the largest wear area regardless of the spindle speed. 0° fibers create the lowest wear in each category. Tool wear changes the chip formation mode, and the machined surface determines the severity of tool wear. Soft and hard abrasion are noticed in CFRP machining regardless of fiber properties. However, relatively more evidences of hard abrasion by intermediate modulus fiber implies the potential dominance of tensile strength in determining the abrasiveness of the carbon fibers. Regarding the drilling of CFRP, (AlCrSi/Ti)N coated drill performed better in determining the hole quality due to the least amount of tool wear among all three drills. Honed and chamfered cutting edge have been identified in CFRP drilling. The micro-geometry of the cutting edges has significant influences on hole quality, especially hole diameter, roundness and surface roughness.
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Details
- Title
- Effects of fiber orientations and properties on tool wear and machined surface quality in machining of carbon fiber reinforced plastics laminate
- Creators
- Mohammad Sayem Bin Abdullah
- Contributors
- Dae-Wook Kim (Advisor) - Washington State University, School of Engineering and Computer Science (VANC)
- Awarding Institution
- Washington State University
- Academic Unit
- School of Engineering and Computer Science (VANC)
- Theses and Dissertations
- Master of Science (MS), Washington State University
- Publisher
- Washington State University
- Identifiers
- 99900890796801842
- Language
- English
- Resource Type
- Thesis