Machining technology for composite materials Principles and practice Edited by H. Hocheng WP WOODHEAD PUBLISHING, ^ Oxford Cambridge Philadelphia New Delhi
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 3 1.2 Turning of metal matrix composites (MMCs) 6 1.3 Cutting tools for turning Al/SiC based MMCs 8 1.4 Cutting with rotary tools 11 1.5 Conclusions 13 1.6 References 14 2 Drilling processes for composites 17 C. C. Tsao, Tahua Institute of Technology, Taiwan 2.1 Introduction 17 2.2 Delamination analysis 19 2.3 Delamination analysis of special drills 22 2.4 Delamination analysis of compound drills 35 2.5 Delamination measurement and assessment 49 2.6 Influence of drilling parameters on drilling-induced delamination 55 2.7 Conclusions 59 2.8 References 60 v
vi Contents 3 Grinding processes for polymer matrix composites 65 S. D. El Wakil, The University of Massachusetts Dartmouth, USA 3.1 Introduction 65 3.2 Applications of grinding processes for composites 66 3.3 Problems associated with the grinding of composites 67 3.4 Various factors affecting the grinding of composites 70 3.5 Future trends 73 3.6 Sources of further information 73 3.7 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 75 4.2 Orthogonal cutting of unidirectional composites 76 4.3 Drilling 94 4.4 Milling 103 4.5 Conclusions and recommended future research 106 4.6 Sources of further information 108 4.7 References 109 4.8 Appendix: List of symbols used 114 5 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 116 5.2 Tool materials 118 5.3 Tool wear 123 5.4 Tool wear in machining metal matrix composites 128 5.5 Tool wear in machining polymeric matrix composites 137 5.6 Tool life 143 5.7 Conclusions 150 5.8 References 151 6 Analyzing surface quality in machined composites 154 K. Palanikumar, Sri Sairam Institute of Technology, India 6.1 Introduction 154 6.2 General concepts of an engineering surface 155 6.3 Surface quality in machining 158 6.4 Influence of cutting parameters on surface quality 163 6.5 Conclusions 178 6.6 References 180
Contents vii Part II Non-traditional methods for machining composite materials 183 7 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 185 7.2 Ultrasonic vibration-assisted (UV-A) turning 186 7.3 UV-A drilling 187 7.4 UV-A grinding 189 7.5 Ultrasonic machining (USM) 190 7.6 Rotary ultrasonic machining (RUM) 193 7.7 UV-A laser-beam machining (LBM) 195 7.8 UV-A electrical discharge machining (EDM) 195 7.9 Conclusions 196 7.10 References 198 8 Electrical discharge machining of composites 202 B. Lauwers, J. Vleugels, O. Malek, K. Brans, and K. Liu, Katholieke Universiteit Leuven, Belgium 8.1 Introduction 202 8.2 Principles of electrical discharge machining (EDM) 204 8.3 Electrically conductive ceramic materials and composites 207 8.4 EDM of ceramic composites: understanding the process-material interaction 213 8.5 New generator technology for EDM 233 8.6 EDM strategies and applications 235 8.7 Conclusions 238 8.8 Acknowledgments 238 8.9 References 240 9 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 242 9.2 The principles of electrochemical discharge machining (ECDM) 244 9.3 ECDM equipment 247 9.4 Parameters affecting material removal rate (MRR) 251 9.5 Parameters affecting surface roughness 258 9.6 Conclusions 261 9.7 Acknowledgement 263 9.8 References 263 Woodhead Publishing Limited, 2012
viii Contents 10 Fundamentals of laser machining of composites 266 G. Chryssolouris and K. Salonitis, University of Patras, Greece 10.1 Introduction 266 10.2 Fundamentals of laser machining 268 10.3 Laser machining of metal matrix composites (MMCs) 274 10.4 Laser machining of non-metallic composites 279 10.5 Conclusions 285 10.6 References 285 11 Laser machining of fibre-reinforced polymeric composite materials 288 R. Negarestani and L. Li, The University of Manchester, UK 11.1 Introduction 288 11.2 Effect of laser and process gas 290 11.3 Effect of materials 301 11.4 Quality criteria 303 11.5 Conclusions 305 11.6 References 305 12 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 309 12.2 Carbon fiber reinforced polymer (CFRP) repair principles 310 12.3 UV laser-cfrp interaction 313 12.4 The laser-based repair process for CFRP 320 12.5 Conclusions 327 12.6 References 329 Part III Special topics in machining composite materials 331 13 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 333 13.2 Overview of high speed drilling (HSD) of fiber-reinforced polymers (FRPs) 336
Contents ix 13.3 Thermal aspects and cutting forces in HSD of FRPs 337 13.4 Tribological aspects in HSD of FRPs 341 13.5 Hole quality 346 13.6 Overview of high speed milling of FRPs 351 13.7 Dynamic characteristics in high speed milling of FRPs 353 13.8 Cutting forces and thermal aspect in high speed milling of FRPs 354 13.9 Surface quality and geometrical errors 359 13.10 References 361 14 Cryogenic machining of composites 365 Y. Yildiz, Dumlupinar University, Turkey and M. M. Sundaram, University of Cincinnati, USA 14.1 Introduction 365 14.2 Key aspects of cryogenic science 368 14.3 State-of-the-art cryogenic machining 377 14.4 Cryogenic machinability of composite materials 382 14.5 Conclusions 388 14.6 Acknowledgments 388 14.7 References 388 15 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 394 15.2 Chip formation 401 15.3 Effect of particle shape 404 15.4 Effect of particle size 405 15.5 Effect of particle volume fraction on tool wear and cutting forces 408 15.6 Conclusions 409 15.7 References 410 16 Machining processes for wood-based composite materials 412 - G. Kowaluk, Warsaw University of Life Sciences SGGW, Poland 16.1 Introduction 412 16.2 Wood-based composite materials 413 16.3 Major machining techniques 415
x Contents 16.4 Selected machining problems 418 16.5 Future trends 422 16.6 Conclusions 424 16.7 References 424 17 Machining metal matrix composites using diamond tools 426 S. S. Joshi, Indian Institute of Technology Bombay, India 17.1 Introduction 426 17.2 Tool life, productivity and tool failure/wear mechanisms 428 17.3 Machined surface and sub-surface integrity 438 17.4 Chip formation and mechanics of machining 446 17.5 Conclusions and future trends 454 17.6 Acknowledgments 455 17.7 References 456 Index 461