Modelling effect of cutter geometrical feature for trimming CFRP composite

Mohd Zakaria, Muhammad Akmal (2014) Modelling effect of cutter geometrical feature for trimming CFRP composite. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Carbon Fibre Reinforced Polymer (CFRP) has found widely used for multi- purpose in many of industries, especially in aerospace industries due to the great in strength to weight ratio as well as the ability to create large integrated structure. In a CFRP panel or the like, a peripheral portion becomes a region having an unstable quality because of the production process. In practice the part is ideally been fabricated oversize and will be trimmed using cutter to obtains the specific size. Due to the inhomogeneous nature of CFRP composite, the trimming process can be challenging. To secured a good surface finish CFRP part, understanding the phenomenon during the material removal is crucial and should be methodically analysed. Accurate prediction of the trimming result will allow development of standard in processing CFRP and able to optimize the parameter that controls the risk of consequences. In this report, a new methodology for the prediction of composite trimming is presented. This report also aims to study the effects left and right tool helical features on the CFRP trimming. The prediction methodology is based on a combination of finite element analysis (FEA) method. It consists the model of the prediction, which is used to take into account the tool- work geometries on material removal during the trimming process. The prediction values have been validated by trimming tests on a CFRP panel with different type of the tool helix angle. This report may assist in enriching the knowledge and understanding of effects of left and right tool helical features. The left helical features serve as a secondary material remover whereby it removes excess material from right helical features as a primary material remover. This research also illustrated the differences of approach that used to indicate the results on surface roughness by using chips formations. In the sense of reducing computing time, this model has proven to employ shell elements to model the three dimensional parts.

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