Influence of Thermal Damage on the Mechanical Strength of Trimmed CFRP
Carbon Fiber Reinforced Plastics (CFRPs) are widely
used for advanced applications, in particular in aerospace, automotive
and wind energy industries. Once cured to near net shape, CFRP
parts need several finishing operations such as trimming, milling or
drilling in order to accommodate fastening hardware and meeting the
final dimensions. The present research aims to study the effect of the
cutting temperature in trimming on the mechanical strength of high
performance CFRP laminates used for aeronautics applications. The
cutting temperature is of great importance when dealing with
trimming of CFRP. Temperatures higher than the glass-transition
temperature (Tg) of the resin matrix are highly undesirable: they
cause degradation of the matrix in the trimmed edges area, which can
severely affect the mechanical performance of the entire component.
In this study, a 9.50mm diameter CVD diamond coated carbide tool
with six flutes was used to trim 24-plies CFRP laminates. A
300m/min cutting speed and 1140mm/min feed rate were used in the
experiments. The tool was heated prior to trimming using a
blowtorch, for temperatures ranging from 20°C to 300°C. The
temperature at the cutting edge was measured using embedded KType
thermocouples. Samples trimmed for different cutting
temperatures, below and above Tg, were mechanically tested using
three-points bending short-beam loading configurations. New cutting
tools as well as worn cutting tools were utilized for the experiments.
The experiments with the new tools could not prove any correlation
between the length of cut, the cutting temperature and the mechanical
performance. Thus mechanical strength was constant, regardless of
the cutting temperature. However, for worn tools, producing a cutting
temperature rising up to 450°C, thermal damage of the resin was
observed. The mechanical tests showed a reduced mean resistance in
short beam configuration, while the resistance in three point bending
decreases with increase of the cutting temperature.
[1] Sadat, A. B., "Delamination and other types of damage of
graphite/epoxy composite caused by machining." Machining of
advanced materials, Vol. 41-52, 1995.
[2] Wang, D. H., Ramulu M., Arola D., "Orthogonal cutting mechanisms of
graphite/epoxy composite. Part I: unidirectional laminate." International
Journal of Machine Tools and Manufacture, Vol. 35, No. 12, pp. 1623-
1638, 1995.
[3] Ramulu, M., "Preliminary investigation of machining effects on the
surface integrity of fiber reinforced plastics." ASME, Petroleum
Division, 1994.
[4] Sheikh-Ahmad J., N. U., Hossein Cheraghi, "Machining Damage in
Edge Trimming of CFRP." Materials and Manufacturing Processes,
Vol. 27, No. 7, pp. 802-808, 2012.
[5] Bhatnagar, N., Nayak D., Singh I., Chouhan H., Mahajan P.,
"Determination of Machining-Induced Damage Characteristics of Fiber
Reinforced Plastic Composite Laminates." Materials and Manufacturing
Processes, Vol. 19, No. 6, pp. 1009-1023, 2004.
[6] Ghidossi, P., El Mansori M., Pierron F., "Influence of specimen
preparation by machining on the failure of polymer matrix off-axis
tensile coupons." Composites Science and Technology, Vol. 66 No. 11–
12, pp. 1857-1872, 2006.
[7] Valavan, U., “Tool life prediction based on cutting forces and surface
temperature in edge trimming of multidirectional CFRP composites”,
Thesis, Wichita State University, 2007.
[8] Y. Turki, M. H., R. Velasco, P. Vantomme, Z. Aboura, "Étude
expérimentale du détourage d’un composite carbone/époxy." 7ème
colloque national de la recherche dans les IUT, 2011.
[9] Bérubé, S., "Usinage en détourage de laminés composites
carbone/époxy." Master thesis, École de Technologie Supérieure ,
Québec, Canada, 2012.
[10] Arola, D. and M. Ramulu, "Net shape manufacturing and the
performance of polymer composites under dynamic loads."
Experimental Mechanics, Vol. 37, No. 4, pp. 379-385, 1997.
[11] Nor Khairusshima, M. K., Che Hassan C.H., Jaharan A.G., Amin
A.K.M., Md Idriss A.N., "Effect of chilled air on tool wear and
workpiece quality during milling of carbon fibre-reinforced plastic."
Wear, Vol. 302, No. 1–2, pp. 1113-1123, 2013.
[12] Shigehiko Sakamoto, H. I., "Effect of Cutting Revolution Speed on
Cutting Temperature in Helical Milling of CFRP Composite Laminates."
Key Engineering Materials, pp.523-524, 2012.
[13] Madjid Haddad, R. Z., Florent Eyma, Bruno Castanié, "Machinability
and surface quality during high speed trimming of multi directional
CFRP." Int. J. of Machining and Machinability of Materials, Vol, 13,
No.2/3, pp. 289-310, 2013.
[14] Takashi I., M. H., Masao Matsui, Liwei Gu (2009). "Cutting
Characteristics of CFRP Materials with End Milling." Key Engineering
Materials, Vol. 407-408, pp. 710-713, 2009. [15] Takashi I., M. H., "Cutting characteristics of CFRP materials with
carbon fiber distribution." International Journal of Automation
Technology, Vol. 7, No. 3, pp. 285-291, 2013
[16] Han Shengchao, C. Y., Xu Jiuhua, Zhou Jingwen, "Experimental Study
of Tool Wear in Milling Multidirectional CFRP Laminates." Materials
Science Forum, Vol. 770, pp. 276-280, 2013.
[17] Yashiro, T., Ogawa T., Sasahara H., "Temperature measurement of
cutting tool and machined surface layer in milling of CFRP."
International Journal of Machine Tools and Manufacture, Vol. 70, No.
0, pp. 63-69, 2013.
[18] Chatterjee, A., "Thermal degradation analysis of thermoset resins."
Journal of Applied Polymer Science, Vol. 114, No.3, pp. 1417-1425,
2009.
[19] Frame, B. J. J., Simpson, W. A., Ziegler, R. E., Philpot, H. E.,
"Composite Heat Damage." Oak Ridge National Laboratory: Oak Ridge
Parts 1 and 2, 1990.
[20] Haskins, J. F., "Thermal ageing." SAMPE Journal, Vol. 25, No. 2, pp.
29-33, 1989.
[21] Luoma, G. A. and R. D. Rowland, "Environmental degradation of an
epoxy resin matrix." Journal of Applied Polymer Science, Vol. 32, No.7,
pp. 5777-5790, 1986.
[22] Herzog, D., Jaeschke P., Meier O., Haferkamp H., "Investigations on the
thermal effect caused by laser cutting with respect to static strength of
CFRP." International Journal of Machine Tools and Manufacture, Vol.
48, No.12–13, pp.1464-1473, 2008.
[23] Yoshihisa Harada, K. K., Takayuki Suzuki, Tokuo Teramoto,
"Evaluation of Cutting Process on the Tensile and Fatigue Strength of
CFRP Composites." Materials Science Forum, Vol. 706-709, pp. 649-
654, 2012.
[24] Hamedanianpour H., Chatelain J.-F, “Effect of Tool Wear on Quality of
Carbon Fiber Reinforced Polymer Laminate during Edge Trimming”,
Applied Mechanics and Materials, Vol. 325-326, pp.34-39, 2013.
[1] Sadat, A. B., "Delamination and other types of damage of
graphite/epoxy composite caused by machining." Machining of
advanced materials, Vol. 41-52, 1995.
[2] Wang, D. H., Ramulu M., Arola D., "Orthogonal cutting mechanisms of
graphite/epoxy composite. Part I: unidirectional laminate." International
Journal of Machine Tools and Manufacture, Vol. 35, No. 12, pp. 1623-
1638, 1995.
[3] Ramulu, M., "Preliminary investigation of machining effects on the
surface integrity of fiber reinforced plastics." ASME, Petroleum
Division, 1994.
[4] Sheikh-Ahmad J., N. U., Hossein Cheraghi, "Machining Damage in
Edge Trimming of CFRP." Materials and Manufacturing Processes,
Vol. 27, No. 7, pp. 802-808, 2012.
[5] Bhatnagar, N., Nayak D., Singh I., Chouhan H., Mahajan P.,
"Determination of Machining-Induced Damage Characteristics of Fiber
Reinforced Plastic Composite Laminates." Materials and Manufacturing
Processes, Vol. 19, No. 6, pp. 1009-1023, 2004.
[6] Ghidossi, P., El Mansori M., Pierron F., "Influence of specimen
preparation by machining on the failure of polymer matrix off-axis
tensile coupons." Composites Science and Technology, Vol. 66 No. 11–
12, pp. 1857-1872, 2006.
[7] Valavan, U., “Tool life prediction based on cutting forces and surface
temperature in edge trimming of multidirectional CFRP composites”,
Thesis, Wichita State University, 2007.
[8] Y. Turki, M. H., R. Velasco, P. Vantomme, Z. Aboura, "Étude
expérimentale du détourage d’un composite carbone/époxy." 7ème
colloque national de la recherche dans les IUT, 2011.
[9] Bérubé, S., "Usinage en détourage de laminés composites
carbone/époxy." Master thesis, École de Technologie Supérieure ,
Québec, Canada, 2012.
[10] Arola, D. and M. Ramulu, "Net shape manufacturing and the
performance of polymer composites under dynamic loads."
Experimental Mechanics, Vol. 37, No. 4, pp. 379-385, 1997.
[11] Nor Khairusshima, M. K., Che Hassan C.H., Jaharan A.G., Amin
A.K.M., Md Idriss A.N., "Effect of chilled air on tool wear and
workpiece quality during milling of carbon fibre-reinforced plastic."
Wear, Vol. 302, No. 1–2, pp. 1113-1123, 2013.
[12] Shigehiko Sakamoto, H. I., "Effect of Cutting Revolution Speed on
Cutting Temperature in Helical Milling of CFRP Composite Laminates."
Key Engineering Materials, pp.523-524, 2012.
[13] Madjid Haddad, R. Z., Florent Eyma, Bruno Castanié, "Machinability
and surface quality during high speed trimming of multi directional
CFRP." Int. J. of Machining and Machinability of Materials, Vol, 13,
No.2/3, pp. 289-310, 2013.
[14] Takashi I., M. H., Masao Matsui, Liwei Gu (2009). "Cutting
Characteristics of CFRP Materials with End Milling." Key Engineering
Materials, Vol. 407-408, pp. 710-713, 2009. [15] Takashi I., M. H., "Cutting characteristics of CFRP materials with
carbon fiber distribution." International Journal of Automation
Technology, Vol. 7, No. 3, pp. 285-291, 2013
[16] Han Shengchao, C. Y., Xu Jiuhua, Zhou Jingwen, "Experimental Study
of Tool Wear in Milling Multidirectional CFRP Laminates." Materials
Science Forum, Vol. 770, pp. 276-280, 2013.
[17] Yashiro, T., Ogawa T., Sasahara H., "Temperature measurement of
cutting tool and machined surface layer in milling of CFRP."
International Journal of Machine Tools and Manufacture, Vol. 70, No.
0, pp. 63-69, 2013.
[18] Chatterjee, A., "Thermal degradation analysis of thermoset resins."
Journal of Applied Polymer Science, Vol. 114, No.3, pp. 1417-1425,
2009.
[19] Frame, B. J. J., Simpson, W. A., Ziegler, R. E., Philpot, H. E.,
"Composite Heat Damage." Oak Ridge National Laboratory: Oak Ridge
Parts 1 and 2, 1990.
[20] Haskins, J. F., "Thermal ageing." SAMPE Journal, Vol. 25, No. 2, pp.
29-33, 1989.
[21] Luoma, G. A. and R. D. Rowland, "Environmental degradation of an
epoxy resin matrix." Journal of Applied Polymer Science, Vol. 32, No.7,
pp. 5777-5790, 1986.
[22] Herzog, D., Jaeschke P., Meier O., Haferkamp H., "Investigations on the
thermal effect caused by laser cutting with respect to static strength of
CFRP." International Journal of Machine Tools and Manufacture, Vol.
48, No.12–13, pp.1464-1473, 2008.
[23] Yoshihisa Harada, K. K., Takayuki Suzuki, Tokuo Teramoto,
"Evaluation of Cutting Process on the Tensile and Fatigue Strength of
CFRP Composites." Materials Science Forum, Vol. 706-709, pp. 649-
654, 2012.
[24] Hamedanianpour H., Chatelain J.-F, “Effect of Tool Wear on Quality of
Carbon Fiber Reinforced Polymer Laminate during Edge Trimming”,
Applied Mechanics and Materials, Vol. 325-326, pp.34-39, 2013.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:71197", author = "Guillaume Mullier and Jean François Chatelain", title = "Influence of Thermal Damage on the Mechanical Strength of Trimmed CFRP", abstract = "Carbon Fiber Reinforced Plastics (CFRPs) are widely
used for advanced applications, in particular in aerospace, automotive
and wind energy industries. Once cured to near net shape, CFRP
parts need several finishing operations such as trimming, milling or
drilling in order to accommodate fastening hardware and meeting the
final dimensions. The present research aims to study the effect of the
cutting temperature in trimming on the mechanical strength of high
performance CFRP laminates used for aeronautics applications. The
cutting temperature is of great importance when dealing with
trimming of CFRP. Temperatures higher than the glass-transition
temperature (Tg) of the resin matrix are highly undesirable: they
cause degradation of the matrix in the trimmed edges area, which can
severely affect the mechanical performance of the entire component.
In this study, a 9.50mm diameter CVD diamond coated carbide tool
with six flutes was used to trim 24-plies CFRP laminates. A
300m/min cutting speed and 1140mm/min feed rate were used in the
experiments. The tool was heated prior to trimming using a
blowtorch, for temperatures ranging from 20°C to 300°C. The
temperature at the cutting edge was measured using embedded KType
thermocouples. Samples trimmed for different cutting
temperatures, below and above Tg, were mechanically tested using
three-points bending short-beam loading configurations. New cutting
tools as well as worn cutting tools were utilized for the experiments.
The experiments with the new tools could not prove any correlation
between the length of cut, the cutting temperature and the mechanical
performance. Thus mechanical strength was constant, regardless of
the cutting temperature. However, for worn tools, producing a cutting
temperature rising up to 450°C, thermal damage of the resin was
observed. The mechanical tests showed a reduced mean resistance in
short beam configuration, while the resistance in three point bending
decreases with increase of the cutting temperature.", keywords = "Composites, Trimming, Thermal Damage, Surface
Quality.", volume = "9", number = "8", pages = "1559-8", }