Machining. composite materials. technology for. Principles and practice. Edited by. H. Hocheng WOODHEAD PUBLISHING

Transcription

1 Machining technology for composite materials Principles and practice Edited by H. Hocheng WP WOODHEAD PUBLISHING, ^ Oxford Cambridge Philadelphia New Delhi

2 Contents Contributor contact details xi Part I Traditional methods for machining composite materials 1 1 Turning processes for metal matrix composites 3 H. A. Kishawy, University of Ontario Institute of Technology (UOIT), Canada 1.1 Introduction Turning of metal matrix composites (MMCs) Cutting tools for turning Al/SiC based MMCs Cutting with rotary tools Conclusions References 14 2 Drilling processes for composites 17 C. C. Tsao, Tahua Institute of Technology, Taiwan 2.1 Introduction Delamination analysis Delamination analysis of special drills Delamination analysis of compound drills Delamination measurement and assessment Influence of drilling parameters on drilling-induced delamination Conclusions References 60 v

3 vi Contents 3 Grinding processes for polymer matrix composites 65 S. D. El Wakil, The University of Massachusetts Dartmouth, USA 3.1 Introduction Applications of grinding processes for composites Problems associated with the grinding of composites Various factors affecting the grinding of composites Future trends Sources of further information Bibliography 74 4 Analysing cutting forces in machining processes for polymer-based composites 75 G. Caprino and A. Langella, University of Naples Federico II, Italy 4.1 Introduction Orthogonal cutting of unidirectional composites Drilling Milling Conclusions and recommended future research Sources of further information References Appendix: List of symbols used Tool wear in machining processes for composites 116 J. Sheikh-Ahmad, The Petroleum Institute, UAE and J. P. Davim, University of Aveiro, Portugal 5.1 Introduction Tool materials Tool wear Tool wear in machining metal matrix composites Tool wear in machining polymeric matrix composites Tool life Conclusions References Analyzing surface quality in machined composites 154 K. Palanikumar, Sri Sairam Institute of Technology, India 6.1 Introduction General concepts of an engineering surface Surface quality in machining Influence of cutting parameters on surface quality Conclusions References 180

4 Contents vii Part II Non-traditional methods for machining composite materials Ultrasonic vibration-assisted (UV-A) machining of composites 185 Q. Feng and C. Z. REN.Tianjin University, China and Z. J. Pei, Kansas State University, USA 7.1 Introduction Ultrasonic vibration-assisted (UV-A) turning UV-A drilling UV-A grinding Ultrasonic machining (USM) Rotary ultrasonic machining (RUM) UV-A laser-beam machining (LBM) UV-A electrical discharge machining (EDM) Conclusions References Electrical discharge machining of composites 202 B. Lauwers, J. Vleugels, O. Malek, K. Brans, and K. Liu, Katholieke Universiteit Leuven, Belgium 8.1 Introduction Principles of electrical discharge machining (EDM) Electrically conductive ceramic materials and composites EDM of ceramic composites: understanding the process-material interaction New generator technology for EDM EDM strategies and applications Conclusions Acknowledgments References Electrochemical discharge machining of particulate reinforced metal matrix composites 242 J. W. Liu, South China University of Technology, China and T. M. Yue, The Hong Kong Polytechnic University, Hong Kong 9.1 Introduction The principles of electrochemical discharge machining (ECDM) ECDM equipment Parameters affecting material removal rate (MRR) Parameters affecting surface roughness Conclusions Acknowledgement References 263 Woodhead Publishing Limited, 2012

5 viii Contents 10 Fundamentals of laser machining of composites 266 G. Chryssolouris and K. Salonitis, University of Patras, Greece 10.1 Introduction Fundamentals of laser machining Laser machining of metal matrix composites (MMCs) Laser machining of non-metallic composites Conclusions References Laser machining of fibre-reinforced polymeric composite materials 288 R. Negarestani and L. Li, The University of Manchester, UK 11.1 Introduction Effect of laser and process gas Effect of materials Quality criteria Conclusions References Laser-based repair for carbon fiber reinforced composites 309 F. Fischer, Laser Zentrum Hannover e. V., Germany, L. Romoli, University of Pisa, Italy and R. Kling and D. Kracht, Laser Zentrum Hannover e.v., Germany 12.1 Introduction Carbon fiber reinforced polymer (CFRP) repair principles UV laser-cfrp interaction The laser-based repair process for CFRP Conclusions References 329 Part III Special topics in machining composite materials High speed machining processes for fiber-reinforced composites 333 H. Attia, National Research Council of Canada, Canada and McGill University, Canada, A. Sadek, McGill University, Canada and M. Meshreki, National Research Council of Canada, Canada 13.1 Introduction Overview of high speed drilling (HSD) of fiber-reinforced polymers (FRPs) 336

6 Contents ix 13.3 Thermal aspects and cutting forces in HSD of FRPs Tribological aspects in HSD of FRPs Hole quality Overview of high speed milling of FRPs Dynamic characteristics in high speed milling of FRPs Cutting forces and thermal aspect in high speed milling of FRPs Surface quality and geometrical errors References Cryogenic machining of composites 365 Y. Yildiz, Dumlupinar University, Turkey and M. M. Sundaram, University of Cincinnati, USA 14.1 Introduction Key aspects of cryogenic science State-of-the-art cryogenic machining Cryogenic machinability of composite materials Conclusions Acknowledgments References Analyzing the machinability of metal matrix composites 394 M. Balazinski, Ecole Polytechnique de Montreal, Canada, V. Songmene, University du Quebec, Canada and H. A. Kishawy, University of Ontario Institute of Technology (UOIT), Canada 15.1 Effect of the nature of the particle: soft and hard particles Chip formation Effect of particle shape Effect of particle size Effect of particle volume fraction on tool wear and cutting forces Conclusions References Machining processes for wood-based composite materials G. Kowaluk, Warsaw University of Life Sciences SGGW, Poland 16.1 Introduction Wood-based composite materials Major machining techniques 415

7 x Contents 16.4 Selected machining problems Future trends Conclusions References Machining metal matrix composites using diamond tools 426 S. S. Joshi, Indian Institute of Technology Bombay, India 17.1 Introduction Tool life, productivity and tool failure/wear mechanisms Machined surface and sub-surface integrity Chip formation and mechanics of machining Conclusions and future trends Acknowledgments References 456 Index 461