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In modern aerospace industry, the use of hybrid CFRP/Ti stacks has experienced an increasing trend because of their enhanced mechanical/physical properties and flexible structural functions. In spite of their widespread applications, machining hybrid CFRP/Ti stacks in one-shot time still consists of the main scientific and technological challenge in the multi-material fastening. Compared to the high cost of pure experimental investigations on the multi-material machining, this study aims to provide an improved CFRP/Ti cutting comprehension via both numerical and experimental methodologies. To this aim, an FE model by using the cohesive zone concept was established to construct the anisotropic machinability of the bi-material structure. The numerical work aims to provide preliminary inspections of the key cutting mechanisms dominating the hybrid CFRP/Ti stack machining. Afterward, some systematic experimental work including orthogonal cutting and hole drilling was carefully performed versus different input cutting conditions. A special focus was made on the study of the effects of different cutting-sequence strategies on CFRP/Ti cutting output and induced interface damage formation. The combined numerical-experimental studies provide the key findings aiming to (i) reveal the activated mechanisms controlling interface cutting and subsequent interface damage formation, (ii) clarify the influences of different cutting-sequence strategies on hybrid CFRP/Ti stack machining, (iii) outline the machinability classification of hybrid CFRP/Ti stacks, and (iv) analyze finally the parametric effects of the material/tool geometry on cutting CFRP/Ti stacks.
This book presents an authoritative account of the potential of advanced composites such as composites, biocomposites, composites geopolymer, hybrid composites and hybrid biocomposites in aerospace application. It documents how in recent years, composite materials have grown in strength, stature, and significance to become a key material of enhanced scientific interest and resultant research into understanding their behavior for selection and safe use in a wide spectrum of technology-related applications. This collection highlights how their unique combination of superior properties such as low density, high strength, high elastic modulus, high hardness, high temperature capability, and excellent chemical and environmental stability are optimized in technologies within these field.
This book provides essential information on environmentally benign/sustainable machining processes including innovations and developments in conventional machining, considering economy, safety, and productivity. Developments in machine tools, recent research on green lubricants and lubrication techniques, process hybridization, and the role of optimization techniques are discussed. Green machining of difficult-to-machine materials and composites is also explained with attempts towards making electric discharge and electrochemical machining technologies. Features: Covers up to date and latest information on environmentally benign machining technologies. Includes current approaches regarding the machinability properties of biomaterials, smart materials, and difficult-to-cut materials. Reviews theoretical understanding and practical aspects of using different technological approaches to attain sustainability in machining. Includes sustainability aspects for both conventional and modern machining. Aids industrial users in the optimum selection of machining parameters with regard to sustainability. This book is aimed at researchers and professionals in manufacturing and mechanical engineering, and sustainable processes.
Special topic volume with invited peer reviewed papers only
Hole-Making and Drilling Technology for Composites: Advantages, Limitations and Potential presents the latest information on hole-making, one of the most commonly used processes in the machining of composites. The book provides practical guidance on hole-making and drilling technology and its application in composite materials and structures. Chapters are designed via selected case studies to identify the knowledge gap in hole-making operations in composites and to highlight the deficiencies of current methods. The book documents the latest research, providing a better understanding of the pattern and characterization of holes produced by various technologies in composite materials. It is an essential reference resource for academic and industrial researchers and professional involved in the manufacturing and machining of composites. In addition, it is ideal for postgraduate students and designers working on the design and fabrication of polymeric composites in automotive and aerospace applications. - Features updated information on the most relevant hole-drilling methods and their potential in aircraft and other structural applications - Features practical guidance for the end user on how to select the most appropriate method when designing fiber-reinforced composite materials - Demonstrates systematic approaches and investigations on the design, development and characterization of 'composite materials'
This book presents select peer-reviewed papers presented at the International Conference on Numerical Optimization in Engineering and Sciences (NOIEAS) 2019. The book covers a wide variety of numerical optimization techniques across all major engineering disciplines like mechanical, manufacturing, civil, electrical, chemical, computer, and electronics engineering. The major focus is on innovative ideas, current methods and latest results involving advanced optimization techniques. The contents provide a good balance between numerical models and analytical results obtained for different engineering problems and challenges. This book will be useful for students, researchers, and professionals interested in engineering optimization techniques.
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 book covers a wide range of conventional and non-conventional machining processes of various composite materials, including polymer and metallic-based composites, nanostructured composites and green/natural composites. It presents state-of-the-art academic work and industrial developments in material fabrication, machining, modelling and applications, together with current practices and requirements for producing high-quality composite components. There are also dedicated chapters on physical properties and fabrication techniques of different composite material groups. The book also has chapters on health and safety considerations when machining composite materials and recycling composite materials. The contributors present machining composite materials in terms of operating conditions; cutting tools; appropriate machines; and typical damage patterns following machining operations. This book serves as a useful reference for manufacturing engineers, production supervisors, tooling engineers, planning and application engineers, and machine tool designers. It can also benefit final-year undergraduate and postgraduate students, as it provides comprehensive information on the machining of composite materials to produce high-quality final components. The book chapters were authored by experienced academics and researchers from four continents and nine countries including Canada, China, Egypt, India, Malaysia, Portugal, Singapore, United Kingdom and the USA.
The present article focuses on analyzing the cutting behavior of the duplex turning process for turn-cut machining of aerospace material, especially for titanium alloy. The experiments are conducted on a homemade setup that was mounted on a lathe machine. Each experiment was replicated twice to avoid variability, and a total of 31 experimental data are collected according to the Central Composite Rotating Design matrix. The feed rate, cutting velocity, and depth of cuts (primary and secondary) are taken as control parameters, while the average surface roughness, primary cutting force, and secondary cutting force are taken as response parameters. The experimental data are used to develop an empirical model using Response Surface Methodology (RSM). The developed RSM model has been experimentally tested and used to generate the response surfaces for parametric studies. Finally, the responses are optimized using D-optimality criteria, and the optimal results are experimentally validated. The result shows that RSM models are well fitted with experimental values with percentage errors of 5.03, 4.77, and 4.87 % for the Fp, Fs, and Ra, respectively. Furthermore, the optimal cutting condition shows significant improvement in the responses, i.e., 4.22, 3.72, and 2.85 % for the Fp, Fs, and Ra, respectively.