Improvement of cutter geometry to enhance machining performance for trimming CFRP composites

Mohamad Noor Adami, Fazreena (2014) Improvement of cutter geometry to enhance machining performance for trimming CFRP composites. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The application of carbon fiber reinforced plastic (CFRP) in industry has increased significantly over the last decade. It is necessary for carrying out post-machining step after curing in order to meet the required tolerances and to manufacture fitting and joining surfaces during machining CFRP composites. Production processes such as milling are mainly use for this. Every process involving CFRP Composites, delamination can occur. This characteristic production defect in CFRP composite is often occur in the top layers of the laminate as these are only supported on one side. This is because top and bottom plies of a multiaxial CFRP tape are even more critical than those of woven fabric, where crossing fibers are mutually supported. Fiber will be cut using the tool in an undefined way, deflect under the action of the cutting edge and consequently delamination occurs in the form of fibres overhang and fibre breakout at the cut edges. Damage to the sample should be minimized, because it takes a long his rehabilitation process and involves high costs and may result in the rejection of components. Most of the existing research in machining CFRP composite concentrates merely on process planning and often neglects the effects of cutter geometric feature which is significantly important. Tool geometric features such as number of teeth and helix angle have direct influence on the cutting performance and should be seriously considered in machining of CFRP composite. This research aims to improve the geometrical cutter feature namely number of teeth and helix angle on the cutting performance of CFRP composite material. The established effects will be used for the development of high performance cutting tool, specifically for trimming CFRP aero composite material.

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