Thesis
Experimental Studies on the Friction Analysis of the Split Sleeve Cold Expansion Process and the Mechanisms of the Carbon Fiber Fabric Cutting Process
Washington State University
Master of Science (MS), Washington State University
2023
DOI:
https://doi.org/10.7273/000005122
Abstract
To characterize the applied molybdenum disulfide-based lubricant in the Split Sleeve Cold Expansion (SSCE) process, two-dimensional tests, “2D Clamp and Pull,” were devised. Resolving the forces in two different dimensions allows Coulomb’s law to be used to determine the friction in the 304 stainless flat sleeves (before they were rolled into the split sleeves used in the SSCE process). An Instron 4482 tensile tester and VPG LCD-10K compression disk sensor mounted on a hydraulic vise were utilized with a crosshead speed of 254mm/min (10in/min). A power law equation for the 2D Clamp and Pull tests was determined for the 0.3048mm (0.012in) thick, 25.4mm (1in) wide flat sleeves at steady state: µ = 0.3577PC^-0.37 with coefficient of friction (µ) and the clamping pressure (PC). The Mass/Area resulted in the lubricant characterization of about 1.6 max/min ratio (left or right sides divided by the center) for the 25.4mm-50.8mm (1in-2.3in) thick flat sleeves; the roughness average yielded about 2.7 max/min ratio for the 25.4mm (1in) width flat sleeves. One-dimensional testing, “1D Clamp and Pull,” was conducted to measure the pulling load and expansion percentage, which replicated the SSCE process using the Instron tensile tester with a commercially available mandrel and split sleeves. For the 2021-T351 custom workpieces, the primary variable impacting the hole expansion was the initial hole diameter.To compare various cutting methods in Hexcel G0926 carbon fiber fabric blanks, three different carbide blade types were tested: utility knife, rotary knife, and Dukane 20khz ultrasonic cutter. The fibers were arranged at 0/90° and 45/135° fiber orientation angles. These tests were conducted on a vacuum plate with a CNC, where the forces were recorded with an Interface 3A120-5KN 3-axis force load cell. Parameters like blade angle (15° or 45° for the utility blades; approximately 11.8° or 41.8° for the ultrasonic cutter) cutting speeds 2.54m/min (100ipm) and 10.2m/min (400ipm). It was determined that the rotary cutter outperformed the utility and ultrasonic cutter’s cut width accuracy due to the large thrust force during the cutting process, with a width of 25.54mm (1.0055in) at 10.2m/min (400in/min).
Metrics
Details
- Title
- Experimental Studies on the Friction Analysis of the Split Sleeve Cold Expansion Process and the Mechanisms of the Carbon Fiber Fabric Cutting Process
- Creators
- Jeremiah James Westrum
- Contributors
- Dave Kim (Advisor)Hua Tan (Committee Member)Chris Qin (Committee Member)
- Awarding Institution
- Washington State University
- Academic Unit
- Engineering and Computer Science (VANC), School of
- Theses and Dissertations
- Master of Science (MS), Washington State University
- Publisher
- Washington State University
- Number of pages
- 111
- Identifiers
- 99901019231401842
- Language
- English
- Resource Type
- Thesis