Effect of Ply Orientation on Roughness for the Trimming Process of CFRP Laminates
The machining of Carbon Fiber Reinforced Plastics
has come to constitute a significant challenge for many fields of
industry. The resulting surface finish of machined parts is of primary
concern for several reasons, including contact quality and impact on
the assembly. Therefore, the characterization and prediction of
roughness based on machining parameters are crucial for costeffective
operations. In this study, a PCD tool comprised of two
straight flutes was used to trim 32-ply carbon fiber laminates in a bid
to analyze the effects of the feed rate and the cutting speed on the
surface roughness. The results show that while the speed has but a
slight impact on the surface finish, the feed rate for its part affects it
strongly. A detailed study was also conducted on the effect of fiber
orientation on surface roughness, for quasi-isotropic laminates used
in aerospace. The resulting roughness profiles for the four-ply
orientation lay-up were compared, and it was found that fiber angle is
a critical parameter relating to surface roughness. One of the four
orientations studied led to very poor surface finishes, and
characteristic roughness profiles were identified and found to only
relate to the ply orientations of multilayer carbon fiber laminates.
[1] Davim J.P., Reis P., Antonio C.C.. "A Study on Milling of Glass Fiber
Reinforced Plastics Manufactured by Hand-lay up Using Statistical
Analysis", Composite Structures, Vol. 64, No. 3, pp. 493-500, 2004.
[2] Davim J.P., Reis P., "Damage and dimensional precision on milling
carbon fiber-reinforced plastics using design experiments", Journal of
Materials Processing Technology, Vol. 160 No. 2, pp. 160-167, 2005.
[3] Palanikumar K., "Cutting Parameters Optimization for Surface
Roughness in Machining of GFRP Composites using Taguchi-s
Method", Journal of Reinforced Plastics and Composites, Vol. 25, No.
16, pp. 1739-1751, 2006.
[4] Palanikumar K., "Surface Roughness Model for Machining Glass Fiber
Reinforced Plastics by PCD Tool using Fuzzy Logics", Journal of
Reinforced Plastics and Composites, Vol. 28 No.18, pp. 2273-2286,
2009.
[5] Rajasekaran T., Vinayagam B.K., Palanikumar K., Prakash S.,
"Influence of Machining Parameters on Surface Roughness and Material
Removal Rate in Machining Carbon Fiber Reinforced Polymer
Material", Frontiers in Automobile and Mechanical Engineering
(FAME), p. 75, 2010.
[6] Eriksen E., "Influence from Production Parameters on the Surface
Roughness of a Machined Short Fiber Reinforced Thermoplastic",
International Journal of Machine Tools and Manufacture, Vol. 39, pp.
1611-1618, 1999.
[7] Palanikumar K., Davim J.P., "Mathematical model to predict tool wear
on the machining of glass fibre reinforced plastic composites", Materials
& Design, Vol. 28, No. 7, pp. 2008-2014, 2007.
[8] Sarma P.M.M.S., Karunamoorthy L., Palanikumar K., Surface roughness
parameters evaluation in machining GFRP composites by PCD tool
using digital image processing, Journal of Reinforced Plastics and
Composites, Vol. 28, No. 13, pp. 1567-1585, 2009.
[9] Jahromi A.S., Gudimani G., Kalla D.K., Bahr B., "Effect of High RPM
Machining and Fiber Orientation On Subsurface Damage in Machining
of Unidirectional Composites", SAMPE 2011 State of the Industry:
Advanced Materials, Applications, and Processing Technologies, Long-
Beach, Ca., 2011.
[10] Chatelain J.-F., Zaghbani I., "Effect of Tool Geometry. Special Features
on Cutting Forces of Multilayered CFRP Laminates", Proc. of the 4th Int.
Conference on Manufacturing Engineering, Quality and Production
Systems, MEQAPS`11, Barcelona, Spain, pp. 85-90, 2011.
[11] Kalla D.,Sheikh-Ahmad J., Twomey J., "Prediction of cutting forces in
helical end milling fiber reinforced polymers", Journal of Machine Tools
and Manufacture, vol. 50, no. 10, pp. 882-891, 2010.
[1] Davim J.P., Reis P., Antonio C.C.. "A Study on Milling of Glass Fiber
Reinforced Plastics Manufactured by Hand-lay up Using Statistical
Analysis", Composite Structures, Vol. 64, No. 3, pp. 493-500, 2004.
[2] Davim J.P., Reis P., "Damage and dimensional precision on milling
carbon fiber-reinforced plastics using design experiments", Journal of
Materials Processing Technology, Vol. 160 No. 2, pp. 160-167, 2005.
[3] Palanikumar K., "Cutting Parameters Optimization for Surface
Roughness in Machining of GFRP Composites using Taguchi-s
Method", Journal of Reinforced Plastics and Composites, Vol. 25, No.
16, pp. 1739-1751, 2006.
[4] Palanikumar K., "Surface Roughness Model for Machining Glass Fiber
Reinforced Plastics by PCD Tool using Fuzzy Logics", Journal of
Reinforced Plastics and Composites, Vol. 28 No.18, pp. 2273-2286,
2009.
[5] Rajasekaran T., Vinayagam B.K., Palanikumar K., Prakash S.,
"Influence of Machining Parameters on Surface Roughness and Material
Removal Rate in Machining Carbon Fiber Reinforced Polymer
Material", Frontiers in Automobile and Mechanical Engineering
(FAME), p. 75, 2010.
[6] Eriksen E., "Influence from Production Parameters on the Surface
Roughness of a Machined Short Fiber Reinforced Thermoplastic",
International Journal of Machine Tools and Manufacture, Vol. 39, pp.
1611-1618, 1999.
[7] Palanikumar K., Davim J.P., "Mathematical model to predict tool wear
on the machining of glass fibre reinforced plastic composites", Materials
& Design, Vol. 28, No. 7, pp. 2008-2014, 2007.
[8] Sarma P.M.M.S., Karunamoorthy L., Palanikumar K., Surface roughness
parameters evaluation in machining GFRP composites by PCD tool
using digital image processing, Journal of Reinforced Plastics and
Composites, Vol. 28, No. 13, pp. 1567-1585, 2009.
[9] Jahromi A.S., Gudimani G., Kalla D.K., Bahr B., "Effect of High RPM
Machining and Fiber Orientation On Subsurface Damage in Machining
of Unidirectional Composites", SAMPE 2011 State of the Industry:
Advanced Materials, Applications, and Processing Technologies, Long-
Beach, Ca., 2011.
[10] Chatelain J.-F., Zaghbani I., "Effect of Tool Geometry. Special Features
on Cutting Forces of Multilayered CFRP Laminates", Proc. of the 4th Int.
Conference on Manufacturing Engineering, Quality and Production
Systems, MEQAPS`11, Barcelona, Spain, pp. 85-90, 2011.
[11] Kalla D.,Sheikh-Ahmad J., Twomey J., "Prediction of cutting forces in
helical end milling fiber reinforced polymers", Journal of Machine Tools
and Manufacture, vol. 50, no. 10, pp. 882-891, 2010.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:50259", author = "Jean François Chatelain and Imed Zaghbani and Joseph Monier", title = "Effect of Ply Orientation on Roughness for the Trimming Process of CFRP Laminates", abstract = "The machining of Carbon Fiber Reinforced Plastics
has come to constitute a significant challenge for many fields of
industry. The resulting surface finish of machined parts is of primary
concern for several reasons, including contact quality and impact on
the assembly. Therefore, the characterization and prediction of
roughness based on machining parameters are crucial for costeffective
operations. In this study, a PCD tool comprised of two
straight flutes was used to trim 32-ply carbon fiber laminates in a bid
to analyze the effects of the feed rate and the cutting speed on the
surface roughness. The results show that while the speed has but a
slight impact on the surface finish, the feed rate for its part affects it
strongly. A detailed study was also conducted on the effect of fiber
orientation on surface roughness, for quasi-isotropic laminates used
in aerospace. The resulting roughness profiles for the four-ply
orientation lay-up were compared, and it was found that fiber angle is
a critical parameter relating to surface roughness. One of the four
orientations studied led to very poor surface finishes, and
characteristic roughness profiles were identified and found to only
relate to the ply orientations of multilayer carbon fiber laminates.", keywords = "Roughness, Detouring, Composites, Aerospace", volume = "6", number = "8", pages = "1389-7", }