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This book covers current advances and practices in machining fibre-reinforced polymer composites under various conventional and nonconventional processes. It presents recent research and practices for effective and efficient machining of difficult-to-cut material, providing the technological ‘know-how’ on delamination-free of drilling, milling, trimming, and other cutting processes on fibre-reinforced polymer composites. It also guides the reader on the selection of optimum machining parameters, tool materials, as well as tool geometry. This book is of interest to academicians, students, researchers, practitioners, and industrialists working in aerospace, automotive, marine, and construction industries.
This excellent volume will serve as an indispensable reference and source book for process design, tool and production engineers in composite manufacturing. It provides the reader with a comprehensive treatment of the theory of machining as it applies to fiber reinforced polymer composites. It covers the latest technical advances in the area of machining and tooling, and discusses the applications of fiber reinforced polymer composites in the aircraft and automotive industries.
Presents polymer-based fibre reinforced composite materials and addresses the characteristics of these widely used materials like low density and coefficient of thermal expansion, specific strength with better fatigue resistance and modulus. The topics discussed are laser-based material machining, high-speed robotic end milling and LFRP modeling, including definitions, features, machine elements (system set-up) as well as experimental and theoretical investigations. These investigations include effects of input variables (tool rotation speed, feed rate and ultrasonic power) on cutting force, torque, cutting temperature, edge quality, surface roughness, burning of machined surface, tool wear, material removal rate, power consumption and feasible regions. Further a detailed literature review on drilling polymer composites with a focus on delamination is included. Aspects such as delamination mechanisms, fabrication methods, the type of drilling process adopted by various researchers, cutting parameters employed during drilling, mathematical delamination modelling, effect of thrust force, spindle speed, thermal loads, tool wear, surface roughness, tool geometry and tool materials on delamination and hole quality are summarized. In addition an approach of digital image processing in delamination assessment completes the approach. - Discusses Carbon Fiber Reinforced Plastics modern technologies for automated, highly productive and cost efficient processing. - Great value for final undergraduate engineering courses or as a topic on manufacturing with FRPs at the postgraduate level as well as a useful reference for academics, researchers, manufacturing, mechanical and materials engineers, professionals in machining of FRPs and related industries.
Presents polymer-based fibre reinforced composite materials and addresses the characteristics of these widely used materials like low density and coefficient of thermal expansion, specific strength with better fatigue resistance and modulus. The topics discussed are laser-based material machining, high-speed robotic end milling and LFRP modeling, including definitions, features, machine elements (system set-up) as well as experimental and theoretical investigations. These investigations include effects of input variables (tool rotation speed, feed rate and ultrasonic power) on cutting force, torque, cutting temperature, edge quality, surface roughness, burning of machined surface, tool wear, material removal rate, power consumption and feasible regions. Further a detailed literature review on drilling polymer composites with a focus on delamination is included. Aspects such as delamination mechanisms, fabrication methods, the type of drilling process adopted by various researchers, cutting parameters employed during drilling, mathematical delamination modelling, effect of thrust force, spindle speed, thermal loads, tool wear, surface roughness, tool geometry and tool materials on delamination and hole quality are summarized. In addition an approach of digital image processing in delamination assessment completes the approach. - Discusses Carbon Fiber Reinforced Plastics modern technologies for automated, highly productive and cost efficient processing. - Great value for final undergraduate engineering courses or as a topic on manufacturing with FRPs at the postgraduate level as well as a useful reference for academics, researchers, manufacturing, mechanical and materials engineers, professionals in machining of FRPs and related industries.
Presents Polymer-based fibre reinforced composite materials and addresses the characteristics like low density and coefficient of thermal expansion, specific strength with better fatigue resistance and modulus. The authors attend to the application problematic given that the structural components integration requires machining even after they precisely fabricated in most of the high production rate industries like aerospace and automobiles.
This brief focus on drilling of polymer matrix composites for aerospace and defence applications. It gives an introduction to machining of polymer composites and discusses drilling as a processing of composites.
More and more companies manufacture reinforced composite products. To meet the market need, researchers and industries are developing manufacturing methods without a reference that thoroughly covers the manufacturing guidelines. Composites Manufacturing: Materials, Product, and Process Engineering fills this void. The author presents a fundamental
The trend in the applications of advanced composite materials, namely the fibrereinforced polymer (FRP) composites, ranges from high performance industrial products to the low end consumer goods. These composite products are commonly fabricated to near-net shapes with finishing steps that involve machining being the integral part of component manufacture. However, the composite machining becomes a challenge compared to that of the conventional metallic materials due to their inherent properties. The damage susceptibility of the FRP composites impedes the consistency of machining quality, whereas the abrasiveness of the workpiece material inflicts rapid wear on the cutting tools. As a result, extensive scientific research has been devoted to investigate the machinability of these materials in order to elucidate their fundamental machining characteristics. Although much attention on turning and drilling of FRP composites can be traced in the existing literature, only a handful of researchers have reported experimental results on limited aspects of FRP composites milling machinability indices. Hence, this thesis has embarked on a systematic machinability study of end milling glass fibre-reinforced polymer (GFRP) composites. A design of experiment methodology was initially employed to determine the effects of machining parameters on key machinability indices or outputs and the suitable operational or machining parameters (guided by the final applications). On the basis of this parametric study, experimental investigations under a wider range of machining parameters and material characteristics were conducted. From these experiments, the empirical relationships between tool performance (in terms of tool life) and the selected parameters were analysed using the traditional Taylor's tool life equation. The useful life of the cutting tool was found to be well described by the Taylor's equations. The cutting speed was identified as the key parameter in influencing the tool life followed by feed rate and fibre orientation. Surface finish, on the other hand, was found to marginally improve with a higher spindle or cutting speed, but rapidly deteriorated with the increase of feed rate. An acceptable machining quality could be achieved by machining along the fibre orientation despite a higher tool wear rate. It appears from the scanning electron microscopy that the machining induced damage comprises fibre fracture, pull-out or protrusions, delamination damage, and epoxy matrix brittle failure. All of these are attributed to the high machining force and reduction of tool sharpness. The constitutive relationships between the growth of tool wear and the measured machining forces were also studied as a pursuit to monitor the cutting tool condition during machining operation. Although adequate agreement between experimental data can be well achieved using multiple regression analysis, the application of fuzzy logic with neural network model demonstrated a significant improvement in the prediction accuracy. Notably, the accuracies of this model are pronounced as a result of nonlinear fuzzy membership function and its hybrid learning algorithms. This makes it attractive as an indirect tool condition monitoring during the machining operation. Machinability of GFRP composites has also been qualitatively evaluated in terms of chip forming mechanisms. This has been accomplished using a high-speed video camera and a quick-stop method. It is apparent that the heterogeneity and insufficient ductility of the composites have produced discontinuous and fracturing chips under the tested machining parameters. A layer of delaminated chip was formed (under the mild cutting speed) as the tool cutting edge fractured the workpiece material along the fibre orientation. However, the increased cutting speed and fibre orientation accelerate the fracture of chips into smaller segments, which make it difficult to denote any chip formation processes.
Composite Materials and Processing provides the science and technology of processing several composites using different processing methods, and includes collective information on the processing of common and advanced composite materials. It also weighs the advantages and disadvantages of various processing methods. This book is suitable for materia
The study and application of composite materials are a truly interdisciplinary endeavour that has been enriched by contributions from chemistry, physics, materials science, mechanics and manufacturing engineering. The understanding of the interface (or interphase) in composites is the central point of this interdisciplinary effort. From the early development of composite materials of various nature, the optimization of the interface has been of major importance. While there are many reference books available on composite materials, few of them deal specifically with the science and mechanics of the interface of fiber reinforced composites. Further, many recent advances devoted solely to research in composite interfaces have been scattered in a variety of published literature and have yet to be assembled in a readily accessible form. To this end this book is an attempt to bring together recent developments in the field, both from the materials science and mechanics perspective, in a single convenient volume. The central theme of the book is tailoring the interface properties to optimise the mechanical peformance and structural integrity of composites with enhanced strength/stiffness and fracture toughness (or specific fracture resistance). It deals mainly with interfaces in advanced composites made from high performance fibers, such as glass, carbon, aramid, ultra high modulus polyethylene and some inorganic (e.g. B/W, A12O3, SiC) fibers, and matrix materials encompassing polymers, metals/alloys and ceramics. The book is intended to provide a comprehensive treatment of composite interfaces in such a way that it should be of interest to materials scientists, technologists and practising engineers, as well as graduate students and their supervisors in advanced composites. We hope that this book will also serve as a valuable source of reference to all those involved in the design and research of composite interfaces. The book contains eight chapters of discussions on microstructure-property relationships with underlying fundamental mechanics principles. In Chapter 1, an introduction is given to the nature and definition of interfaces in fiber reinforced composites. Chapter 2 is devoted to the mechanisms of adhesion which are specific to each fiber-matrix system, and the physio-chemical characterization of the interface with regard to the origin of adhesion. The experimental techniques that have been developed to assess the fiber-matrix interface bond quality on a microscopic scale are presented in Chapter 3, along with the techniques of measuring interlaminar/intralaminar strengths and fracture toughness using bulk composite laminates. The applicability and limitations associated with loading geometry and interpretation of test data are compared. Chapter 4 presents comprehensive theoretical analyses based on shear-lag models of the single fiber composite tests, with particular interest being placed on the interface debond process and the nature of the fiber-matrix interfacial bonding. Chapter 5 is devoted to reviewing current techniques of fiber surface treatments which have been devised to improve the bond strength and the fiber-matrix compatibility/stability during the manufacturing processes of composites. The micro-failure mechanisms and their associated theories of fracture toughness of composites are discussed in Chapter 6. The roles of the interface and its effects on the mechanical performance of fiber composites are addressed from several viewpoints. Recent research efforts to augment the transverse and interlaminar fracture toughness by means of controlled interfaces are presented in Chapters 7 and 8.