Characterization of Material Properties of Wf-P Composites Exposed to Secondary Manufacturing Processes

Transcription

1 Forest Products Society 6 th Conference on Wf-P Composites Characterization of Material Properties of Wf-P Composites Exposed to Secondary Manufacturing Processes Urs Buehlmann Daniel Saloni Richard L. Lemaster North Carolina State University, Raleigh NC Madison May 16, 2001 slide 1

2 Overview The program - NCSU WMTRP Woodfiber plastic composites - applications Research - overview Sanding Machining Summary of results Future research Questions - Discussion slide 2

3 NCSU - Wood Machining & Tooling Reserach Program founded 1991 Mission: To improve the long-term competitiveness of the wood industry 8 Researchers, 12 Graduate Students, 5 Undergraduate Research Associates Works with industry worldwide 6th International Conference on Woodfiber-Plastic Composites, 05/16/2001 File: pr sec. processing of wf-p composites slide 3

4 Woodfiber plastic composites - APPLICATIONS - Focus on formulations, materials production, materials properties What about secondary processing? What if: wf-p composites become lumber substitutes for the secondary wood products industry? machining (cutting, sanding, routing, etc.) of these materials becomes necessary? slide 4

5 Woodfiber plastic composites - APPLICATIONS - (cont.) Little is known about secondary processing characteristics of these materials Do different brands have different machining characteristics? What are the correct machining parameters for these materials? slide 5

6 Research - overview Dept. of Wood and Paper Science, WMTRP and Polymers Center of Excellence formed group focused on wf-p composites and applications Members so far include: Urs Buehlmann wood and processing Rick Lemaster machining and tooling Daniel Saloni machining and tooling Perry Peralta physics John Kadla chemistry Dan Fuccella polymers Tony LaPasha standards & testing slide 6

7 Research - overview (cont.) First look at two processes: sanding machining (routing) Compare 5 commercially available decking materials: ChoiceDek Excel Fiberon 6th International Conference on Woodfiber-Plastic Composites, 05/16/2001 SmartDeck Trex Pine or Maple (control) File: pr sec. processing of wf-p composites slide 7

8 Sanding Experimental design Experiment Results slide 8

9 Experimental design Pressure Belt Grid (psi) ChoiceDek 0.50 Al 2 O 3 P100 Fiberon 0.50 Al 2 O 3 P100 SmartDeck 0.50 Al 2 O 3 P100 Trex 0.50 Al 2 O 3 P100 Maple 0.50 Al 2 O 3 P100 Excel couldn't be tested due to its hollow core slide 9

10 Experimental design - cont. MRR - material removal rate measured by converting weightloss between two tests into lb/min material loss Surface roughness Belt life measured by using a stylus-type profilometer, and the indicators utilized were Rq and Ra determined doing the sanding process until the difference in weight before and after sanding was not larger than pounds and constant for at least 3 measure. Two specimens per test slide 10

11 Experimental design - cont. Equipment, materials and parameters: Belt Sander Bench (6 x 48 abrasive belt and 2500 SF.P.M. belt speed) Stylus type Profilometer 3M Sanding Belt 6 x 48 Pieces Dimensions: 3 x 4 Pressure 0.50 psi Experiment time: one (1) minute per run slide 11

12 Results - MRR lb/min minutes SMARTDECK FIBERON CHOICEDEK TREX MAPLE slide 12

13 Results - overview view Roughness MRR Average Belt Life (Rq (µin)) (lb/min) (min) ChoiceDek Fiberon SmartDeck Trex Maple Roughness similar for all specimens Average MRR different by factor 2 Belt life shows large differences slide 13

14 Machining Experimental design Experiment Results slide 14

15 β Rake Face Experimental design Standard tool wear test developed previously by the WMTRP Specimens were cut into 23.5 inches long pieces - all six materials Parameter Setting Four runs speed 16 passes 18,000 each rpmfor RR cutting lengths Feed of: speed 31, 63, 94, and ipm feets Depth of cut 1/16 inches pass Measured Carbide the grade tool wear Sandvik after H3F each run on the Length carbide of cutblade 23.5 for inches each NW/ pass of the 6 materials Cuts per test 16 Clearance Face # of tests 4 RR = Edge recession measured parallel to the rake face NW = Initial Mode nose of (edge) cut width of Conventional a sharp tool slide 15

16 width of nose (microns) Results - Tool wear All specimens feet cut ChoiceDek Excel Fiberon SmartDeck Trex Pine slide 16

17 width of of nose (microns) Results - Tool wear (cont.) ChoiceDek 0 feet cut point measured on on blade (microns) Pine slide 17

18 Results - overview view Wear after 125ft Roughness across Roughness border Roughness center across lengtwise microns (Rq (µin)) (Rq (µin)) ChoiceDek Excel 31.5 NA 112 NA Fiberon SmartDeck Trex Pine Large differences in tool wear among products Smaller, but still detectable differences in cutting surface smoothness slide 18

19 Results - Summary Wf-P composite products behave differently to wood when subject to secondary manufacturing processes Different Wf-P composite products behave differently among each other when subject to secondary manufacturing processes Some Wf-P composite products would create proplems when subjected to large scale secondary manufacturing processes slide 19

20 Future research Verify findings from this preliminary research project Research why different products behave differently when exposed to secondary manufacturing processes Work with industry partners on products that will allow the industrial use of wf-p composites for secondary products slide 20

21 THANK YOU! Questions - Discussion slide 21