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Machining of Composites and Multi-Stacks of Aerospace Materials

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A special issue of Materials (ISSN 1996-1944).

Deadline for manuscript submissions: closed (15 July 2016) | Viewed by 30983

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Prof. Dr. Redouane Zitoune

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Université de Toulouse, INSA, UPS, Mines d’Albi, ISAE, ICA (Institut Clément Ader), IUT-A GMP Toulouse, 133 c Avenue de Rangueil, 31077 Toulouse, France
Interests: composite materials; machining; manufacturing engineering; materials science; multifunctional materials; instrumentation
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Special Issue Information

Dear Colleagues,

The aerospace and modern manufacturing industries are driving the use of advanced materials, such as composites, titanium, aluminum, and all combinations of these materials, to constitute the multi-stacks or hybrids materials. The properties of these materials make them difficult to machine. Especially, problems, such as rapid tool wear and chatter, delamination of some composite layers, and thermal (or mechanical) degradation of the matrix during machining of composites. The objectives of this Special Issue, focusing on machining of composites and multi-stacks of aerospace materials, are:

- To provides in depth analysis towards machining of these kinds of materials;

- Influence of the machining process (conventional and non-conventional) and the damages generated;

- Impact of the damages of machining on the structural integrity;

- Understand questions associated with the machinability of these materials.

Assoc. Prof. Dr. Redouane Zitoune
Guest Editor

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Keywords

Machining
Composites
Multi-stacks
Material integrity

Published Papers (5 papers)

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Research

5030 KiB

Open AccessFeature PaperArticle

Characterization and Effects of Fiber Pull-Outs in Hole Quality of Carbon Fiber Reinforced Plastics Composite

by Sina Alizadeh Ashrafi, Peter W. Miller, Kevin M. Wandro and Dave Kim

Materials 2016, 9(10), 828; https://doi.org/10.3390/ma9100828 - 13 Oct 2016

Cited by 33 | Viewed by 6515

Abstract

Hole quality plays a crucial role in the production of close-tolerance holes utilized in aircraft assembly. Through drilling experiments of carbon fiber-reinforced plastic composites (CFRP), this study investigates the impact of varying drilling feed and speed conditions on fiber pull-out geometries and resulting hole quality parameters. For this study, hole quality parameters include hole size variance, hole roundness, and surface roughness. Fiber pull-out geometries are quantified by using scanning electron microscope (SEM) images of the mechanically-sectioned CFRP-machined holes, to measure pull-out length and depth. Fiber pull-out geometries and the hole quality parameter results are dependent on the drilling feed and spindle speed condition, which determines the forces and undeformed chip thickness during the process. Fiber pull-out geometries influence surface roughness parameters from a surface profilometer, while their effect on other hole quality parameters obtained from a coordinate measuring machine is minimal. Full article

(This article belongs to the Special Issue Machining of Composites and Multi-Stacks of Aerospace Materials)

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9294 KiB

Open AccessArticle

High-Speed Edge Trimming of CFRP and Online Monitoring of Performance of Router Tools Using Acoustic Emission

by Rangasamy Prakash, Vijayan Krishnaraj, Redouane Zitoune and Jamal Sheikh-Ahmad

Materials 2016, 9(10), 798; https://doi.org/10.3390/ma9100798 - 26 Sep 2016

Cited by 35 | Viewed by 5939

Abstract

Carbon fiber reinforced polymers (CFRPs) have found wide-ranging applications in numerous industrial fields such as aerospace, automotive, and shipping industries due to their excellent mechanical properties that lead to enhanced functional performance. In this paper, an experimental study on edge trimming of CFRP was done with various cutting conditions and different geometry of tools such as helical-, fluted-, and burr-type tools. The investigation involves the measurement of cutting forces for the different machining conditions and its effect on the surface quality of the trimmed edges. The modern cutting tools (router tools or burr tools) selected for machining CFRPs, have complex geometries in cutting edges and surfaces, and therefore a traditional method of direct tool wear evaluation is not applicable. An acoustic emission (AE) sensing was employed for on-line monitoring of the performance of router tools to determine the relationship between AE signal and length of machining for different kinds of geometry of tools. The investigation showed that the router tool with a flat cutting edge has better performance by generating lower cutting force and better surface finish with no delamination on trimmed edges. The mathematical modeling for the prediction of cutting forces was also done using Artificial Neural Network and Regression Analysis. Full article

(This article belongs to the Special Issue Machining of Composites and Multi-Stacks of Aerospace Materials)

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14161 KiB

Open AccessArticle

Investigation on the Effect of Drill Geometry and Pilot Holes on Thrust Force and Burr Height When Drilling an Aluminium/PE Sandwich Material

by Bruna Aparecida Rezende, Michele L. Silveira, Luciano M. G. Vieira, Alexandre M. Abrão, Paulo Eustáquio de Faria and Juan C. Campos Rubio

Materials 2016, 9(9), 774; https://doi.org/10.3390/ma9090774 - 13 Sep 2016

Cited by 24 | Viewed by 5908

Abstract

Composite materials are widely employed in the naval, aerospace and transportation industries owing to the combination of being lightweight and having a high modulus of elasticity, strength and stiffness. Drilling is an operation generally used in composite materials to assemble the final product. Damages such as the burr at the drill entrance and exit, geometric deviations and delamination are typically found in composites subjected to drilling. Drills with special geometries and pilot holes are alternatives used to improve hole quality as well as to increase tool life. The present study is focused on the drilling of a sandwich composite material (two external aluminum plates bound to a polyethylene core). In order to minimize thrust force and burr height, the influence of drill geometry, the pilot hole and the cutting parameters was assessed. Thrust force and burr height values were collected and used to perform an analysis of variance. The results indicated that the tool and the cutting speed were the parameters with more weight on the thrust force and for burr height they were the tool and the interaction between tool and feed. The results indicated that drilling with a pilot hole of Ø4 mm exhibited the best performance with regard to thrust force but facilitated plastic deformation, thus leading to the elevation of burr height, while the lowest burr height was obtained using the Brad and Spur drill geometry. Full article

(This article belongs to the Special Issue Machining of Composites and Multi-Stacks of Aerospace Materials)

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6584 KiB

Open AccessArticle

Drilling of Hybrid Titanium Composite Laminate (HTCL) with Electrical Discharge Machining

by M. Ramulu and Mathew Spaulding

Materials 2016, 9(9), 746; https://doi.org/10.3390/ma9090746 - 01 Sep 2016

Cited by 26 | Viewed by 5253

Abstract

An experimental investigation was conducted to determine the application of die sinker electrical discharge machining (EDM) as it applies to a hybrid titanium thermoplastic composite laminate material. Holes were drilled using a die sinker EDM. The effects of peak current, pulse time, and percent on-time on machinability of hybrid titanium composite material were evaluated in terms of material removal rate (MRR), tool wear rate, and cut quality. Experimental models relating each process response to the input parameters were developed and optimum operating conditions with a short cutting time, achieving the highest workpiece MRR, with very little tool wear were determined to occur at a peak current value of 8.60 A, a percent on-time of 36.12%, and a pulse time of 258 microseconds. After observing data acquired from experimentation, it was determined that while use of EDM is possible, for desirable quality it is not fast enough for industrial application. Full article

(This article belongs to the Special Issue Machining of Composites and Multi-Stacks of Aerospace Materials)

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6210 KiB

Open AccessFeature PaperArticle

Evaluation of Workpiece Temperature during Drilling of GLARE Fiber Metal Laminates Using Infrared Techniques: Effect of Cutting Parameters, Fiber Orientation and Spray Mist Application

by Khaled Giasin and Sabino Ayvar-Soberanis

Materials 2016, 9(8), 622; https://doi.org/10.3390/ma9080622 - 28 Jul 2016

Cited by 41 | Viewed by 6527

Abstract

The rise in cutting temperatures during the machining process can influence the final quality of the machined part. The impact of cutting temperatures is more critical when machining composite-metal stacks and fiber metal laminates due to the stacking nature of those hybrids which subjects the composite to heat from direct contact with metallic part of the stack and the evacuated hot chips. In this paper, the workpiece surface temperature of two grades of fiber metal laminates commercially know as GLARE is investigated. An experimental study was carried out using thermocouples and infrared thermography to determine the emissivity of the upper, lower and side surfaces of GLARE laminates. In addition, infrared thermography was used to determine the maximum temperature of the bottom surface of machined holes during drilling GLARE under dry and minimum quantity lubrication (MQL) cooling conditions under different cutting parameters. The results showed that during the machining process, the workpiece surface temperature increased with the increase in feed rate and fiber orientation influenced the developed temperature in the laminate. Full article

(This article belongs to the Special Issue Machining of Composites and Multi-Stacks of Aerospace Materials)

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