On the Surface Quality of CFRTP/Steel Hybrid Structures Machined by AWJM (original) (raw)
Related papers
2020
In the present work, effects of abrasive flow rate, stand-off distance and traverse speed has been visualised on surface roughness of CFRP composite material using water submerged Abrasive Water Jet Machining (AWJM). The experiments were conducted based on Response surface design created by MINITAB 17. Regression models were established to predict the correlation between the input process parameters and surface roughness for CFRP. This process is mainly best suited for cutting thermosensitive materials which cannot be machined by. It is very much suitable and economical technique to machine the various types of metals, alloys, polymers, glass fibre metal and composites etc. AWJM process is characterized by several process parameters that influences the machining quality. In this work, effect of parameters viz. traverse speed, stand-off distance and water pressure on surface quality of CFRP composites has been inspected. Response surface methodology is being adopted for experimentati...
Journal of Materials Research and Technology, 2022
Fiber reinforced polymer (FRP) composite materials have huge demand in various fields due to their low weight and better mechanical qualities. Machining of FRP composite materials without damage is quite difficult using traditional machining systems owing to their intrinsic anisotropy, heterogeneity, and temperature sensitivity. Abrasive water jet machining (AWJM) is a known versatile technique to address the machining of FRP composite with minimal damage. However, kerf taper and delamination are the significant damages usually recorded in AWJM. The present work aims to minimize the above-said damages by applying a hybrid grey relational analysis (GRA)-principal component analysis (PCA) mathematical model. The glass and carbon fibers are used as reinforcements in the epoxy matrix. Nine experiments are conducted by considering hydraulic pressure, the mass flow of abrasive, standoff distance and transverse speed as machining parameters at three different levels each. The experimental and empirical results reveal that the mass flow of abrasive and hydraulic pressure are significant parameters to minimize the kerf damage, whereas the mass flow of abrasive and standoff distance are the parameters to reduce the delamination damage. The confirmation experiment based on the recommended optimized parameter records the reduction in delamination damage and kerf width damage to 33.9% and 11.72 %, respectively. The adequacy and accuracy of the proposed mathematical model is being performed with the value of indicators R² and adjR², which are all closer to one.
Experimental and Analysis in Abrasive Water jet cutting of carbon fiber reinforced plastics
2019
Various kinds of processes are used for drilling composites; however every type has their own characteristics. Among these processes, Abrasive water jet machining (AWJM) is largely used in different fields as aerospace industries for machining composites thanks to absence of temperature and contact tool with the work piece. AWJM proved some challenges when cutting carbon fiber reinforced plastic (CFRP) composites materials such as cut accuracy and good surface quality. In the present work, different cutting conditions including abrasive flow rate, jet traverse speed and standoff distance are tested in the cutting of woven fabric carbon reinforced plastics. For the experimental design, response surface methodology (RSM) was used for evaluating the modeling and analysis of responses such as surface roughness and hole taper. The main experimental results demonstrated that the stand-off distance and the abrasive flow rate were the major parameters affecting the surface roughness (Ra) an...
Experimental Investigations into Abrasive Waterjet Machining of Carbon Fiber Reinforced Plastic
Journal of Composites, 2015
Abrasive waterjet machining (AWJM) is an emerging machining process in which the material removal takes place due to abrasion. A stream of abrasive particles mixed with filtered water is subjected to the work surface with high velocity. The present study is focused on the experimental research and evaluation of the abrasive waterjet machining process in order to evaluate the technological factors affecting the machining quality of CFRP laminate using response surface methodology. The standoff distance, feed rate, and jet pressure were found to affect kerf taper, delamination, material removal rate, and surface roughness. The material related parameter, orientation of fiber, has been also found to affect the machining performance. The kerf taper was found to be 0.029 for 45 ∘ fiber orientation whereas it was 0.036 and 0.038 for 60 ∘ and 90 ∘ , respectively. The material removal rate is 18.95 mm 3 /sec for 45 ∘ fiber orientation compared to 18.26 mm 3 /sec for 60 ∘ and 17.4 mm 3 /sec for 90 ∘ fiber orientation. The value for 45 ∘ fiber orientation is 4.911 m and for 60 ∘ and 90 ∘ fiber orientation it is 4.927 m and 4.974 m, respectively. Delamination factor is found to be more for 45 ∘ fiber orientation, that is, 2.238, but for 60 ∘ and 90 ∘ it is 2.029 and 2.196, respectively.
Revue des composites et des matériaux avancés, 2020
The conventional machining of engineering hard materials like composites is a challenging task due to rapid tool wear and high machining cost. In this context, the non-conventional machining such as abrasive waterjet cutting is mostly utilized for the cutting of such hard materials due to its tremendous machining outcomes. Here an attempt is made to cut the previously developed sample of hybrid metal matrix composite A359/B4C/Al2O3 by abrasive waterjet machining process. Three different samples with change proportions of reinforcement from 2% to 4% were used in this study to create the flat machined surfaces. The surface roughness profile and 3D surface detailing are generated through the microprof FRT machine and inbuilt measuring sensor. Result revels that rough cutting with the average surface roughness value ranges from 7 to 9 µm for the selected samples. The machined surface is full of cutting traces with some of macro pores of size 1.2 mm to 1.8 mm observed by 3D profile views.
Abrasive Water Jet Machining of Multidirectional CFRP Laminates
Abrasive water jet machining (AWJM) is widely used in aerospace, marine and automotive industries for trimming composites. However, AWJM demonstrates some challenges when cutting carbon fibre reinforced plastic (CFRP) composites materials such as cut accuracy and quality. More experimental work is needed to provide sufficient machinability databases for manufacturing engineers. This paper presents an experimental study and statistical analysis for cutting 2 lay-up configurations of multidirectional CFRP laminates. Different AWJM conditions including jet pressure, feed rate, and standoff distance are experimented using full factorial design of experiments. Machining process responses such as top and bottom kerf width, kerf taper, machinability and surface characteristics have been evaluated using analysis of variance (ANOVA) technique. A process cost model for the AWJM is presented.
An Experimental Study on Carbon Fiber Reinforced Plastic by using AWJM
international journal for research in applied science and engineering technology ijraset, 2020
Abrasive water jet machining (AWJM) is widely utilized in aerospace, marine and automotive industries for trimming composites. However, it has some challenges when cutting carbon fibre reinforced plastic (CFRP) composites materials such as cut accuracy and quality. More experimental work is required to provide sufficient machinability databases for manufacturing engineers. This paper represents an experimental study and statistical analysis for cutting 2 lay-up configurations of multidirectional CFRP laminates. Different AWJM conditions include jet pressure, feed rate, and standoff distance are experimented using full factorial design of experiments. Machining process responses include top and bottom kerf width, kerf taper, machinability and surface characteristics have been evaluated using analysis of variance (ANOVA) technique. A process cost model for the AWJM is shown.
Machinability And Surface Quality Of Hybrid Composite CFRP/Al2024
2017
The use of hybrid composite has increased due to their special mechanical and physical properties. However, machining of composite materials is extremely difficult due to non-homogeneous, anisotropic and highly abrasive characteristics. The performance of machined surface quality of CFRP/Al2024 was described using two level full factorial methodology. Trimming test was performed under dry conditions using 6mm diameter of burr tools end mills. The factors investigated were spindle speed(N), feed rate(fr) and depth of cut(dc), furthermore Ra CFRP and Ra Al2024 were the response variables. This work aims to minimize the machined surface quality of CFRP/Al2024 between 1μm to 2μm. The finding of this empirical study has shown that, the best estimated value of fr should be 500 mm/min to 530 mm/min, N is between and 2313.870 rpm to 2336.042 rpm. For both response spindle speed is the most significant effect followed by Feed rate and Depth of Cut.
Materials, 2019
Carbon fiber-reinforced thermoplastics (CFRTPs) are materials of great interest in industry. Like thermosets composite materials, they have an excellent weight/mechanical properties ratio and a high degree of automation in their manufacture and recyclability. However, these materials present difficulties in their machining due to their nature. Their anisotropy, together with their low glass transition temperature, can produce important defects in their machining. A process able to machine these materials correctly by producing very small thermal defects is abrasive waterjet machining. However, the dispersion of the waterjet produces a reduction in kinetic energy, which decreases its cutting capacity. This results in an inherent defect called a kerf taper. Also, machining these materials with reduced thicknesses can increase this defect due to the formation of a damage zone at the beginning of cut due to the abrasive particles. This paper studies the influence of cutting parameters o...
Surface quality and kerf width prediction in abrasive water jet machining of metal-composite stacks
Composites Part B: Engineering, 2019
Machinability of stacked Titanium (Ti6Al4V) and CFRP was evaluated using Abrasive Water Jet (AWJ) machining process. The experimental study was conducted using three pressure levels-200, 275 and 350 MPa. Traverse speed was varied between 1 and 10 mm/s for two stacking configurations (Ti/CFRP, and CFRP/Ti). The erosion characteristics, kerf width and surface roughness was studied as a function of process parameters. Surface roughness and kerf width variation was high at low jet power conditions, as described by lumped parameters (Ė/u andĖ/hu). The minimum average roughness R a for Ti and CFRP was less than 3.5 µm and 4.5 µm respectively for both the stacking sequence. The kerf width increased significantly, especially when Ti6Al4V is at top in which case low-energy, turbulent jet diverges at the exit from Ti6Al4V. Mathematical regression models were developed to predict kerf width. An energy based, semi-analytical model was proposed to predict the kerf geometry with R 2 = 92.26%.