Recently, carbon fiber-reinforced plastic (CFRP) has been attracting much attention in various industries because of its beneficial properties such as excellent strength, modulus per unit density, and anti-corrosion properties. However, there are several issues in its application to various fields. Severe tool wear issues in its machining have been noted as one of the most serious problems because it induces various serious machining failures such as delamination and splintering. In this regard, timely tool replacement is essential for reducing the influence of tool wear. In this study, tool wear, especially flank wear, in the CFRP drilling was investigated and monitored. First, the reproducibility of tool wear under the same machining condition was experimentally evaluated. And it is demonstrated that tool wear may remarkably differ even though the same machining condition is applied to the tools. Then, tool wear monitoring based on the feed motor torque was applied to the detection of tool life ending in the CFRP drilling process. Consequently, it was demonstrated that the average and maximum detection error of the tool life end were less than 7 and 14%, respectively.
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Transportation machine manufacturers are putting in efforts on research based on weight reduction. One of the representative materials for weight reduction is Fiber Reinforced Plastic (FRP). Increased used of FRP, glass fiber and carbon fiber could be a way of weight reduction. It is almost unavoidable to generate holes or notches during structural design. Little research have been carried out based on cracks with respect to materials used for design. The utilization of finite element analysis and the reliability of the analysis methods are increasing in order to promptly cope with the damages in materials. In this study, Compact Tension (CT) model based on ASTM E647 was designed using SM45C, steel for structural use, short fiber Glass Fiber Reinforced Plastic (GFRP), and woven type Carbon Fiber Reinforced Plastic (CFRP). In addition, J-Integral, which is a factor for determination of growth of crack that appears in cracks, was applied to general structure analysis. J-Integral is an equation of the body force of the material and strain energy in accordance with the loading force, and illustrates the crack growth using energy release rate. J-Integral values of SM45C, short fiber GFRP and woven type CFRP were found to be approximately 74,978 mJ/mm², 7492.3 mJ/mm² and 6222.4 mJ/mm², respectively.
Carbon Fiber Reinforced Plastic (CFRP) materials which are superlight in weight and have high strength have recently been applied in the automobile and aerospace industry, etc. to achieve high fuel efficiency. CFRP is termed as ‘difficult to cut material’ due to its unique material properties. It’s considered to be highly sensitive in processing due to its laminated structure which would pose some challenges such as delamination, Pull-out, Burr and Uncut. Due to this, it’s maintenance and treatment costs are high. There are also limitations in the conventional Gantry Machine in 3D shape cutting of CFRP materials. To counter this challenge, a robotic abrasive waterjet system with the following features has been developed and installed on site; a high-pressure pump, monitoring system and a catcher for 3D Shape cutting., It’s performance has been successfully proved. Based on the result, we discovered that a 6 axes robot could execute 3D shape cutting of car hood due to its high movement flexibility. In the future it is projected to fulfill more kinds of CFRP materials cutting test on many car brands.
The demand for inspection of high-speed systems for machined Carbon Fiber Reinforced Plastics parts for automobileindustry and aviation industry is constantly rising. One of the factors that degrade the performance of an inspection system is micro-vibration from the ground or structure where is placed. Various isolation systems that suppress the vibration have been studied classified as either passive or active system. The passive system is composed of a spring and a damper while the active system suppresses the vibration through an electronic control system using sensors and actuators. In this study, a voice coil motor (force constant 55N/A) acting as the actuator is optimally designed using permeance method and sequential quadratic programming algorithm to suppress the vibration and reaction force by a specimen moving stage. The two optimized voice coil motors are attached to a pneumatic mount that has an advantage in design based on the force and size constraints required by the user for an active vibration isolator with velocity sensors (GS-11d). The active vibration isolation system with the four active vibration isolators -23 dB and -20 dB at resonance frequencies in horizontal and vertical transmissibility performs better than a passive vibration isolation system.
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Transportation industries, such as aerospace and automotive demand high efficiency using lightweight parts. Carbon Fiber Reinforced Plastics (CFRP) present promising materials for transportation industry parts due to their lightweight and highstrength properties. Forming and machining processes are required to manufacture parts from carbon fiber composite materials. The near-net shaping process forms the parts, and the final accurate shape and hole are accomplished using the machining process. However, high-strength carbon fiber chips and dust from the machining process cause cutting tool wear and low productivity. The hybrid CRD (Cutting, Routing and Drilling)/water-jet machine improves tool life and productivity because its water-jet process, employed before the mechanical machining process cuts roughly without chips and dust. In this study, the hybrid CRD/water-jet machine we developed was introduced and its machining performance was evaluated using a drilling process. The delamination factor and surface roughness of drilled holes were compared with the results from a conventional machine tool.
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Lightweight parts are necessary to improve fuel efficiency and reduce environmental impacts in transportation industry. As a result, there has been a shift away from using conventional metals toward using lighter materials with superior mechanical strength. These new materials typically include titanium alloys, nickel alloys, carbon fiber reinforced plastics (CFRPs), and CFRP-metal stacks, which are classified as advanced materials. However, due to the unique properties of these materials (e.g., high strength, low thermal conductivity, carbon fiber-induced hardness, etc.), the cutting process can be difficult. As a result, various manufacturing issues can occur during the cutting process, such as high tool wear, surface quality deterioration, delamination of the CFRP layer, fiber pull-out, and thermal deformation. In this paper, difficult-to-cut advanced materials were reviewed with regard to the influence of the physical properties of the materials and various defect issues that can occur during the mechanical cutting process. In addition, various approaches to improve the cutting process are introduced, including protecting tools with coatings, altering tool features, using high pressure or cryogenic cooling, extending tool life via ultrasonic vibration machining, and improving product quality and machinability.
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It is generally accepted that mechanical properties of sandwich composite are affected by curing pressure variation. For the present study, the effects of curing pressure variation on the compressive properties of balsa wood sandwich composite were investigated. For this purpose, a compressive test was conducted using balsa wood and honeycomb core sandwich composite, applying 40 psi and 60 psi curing pressure conditions. The results showed that compressive load of balsa wood sandwich composite applying 60 psi curing pressure condition is higher than applying a 40-psi curing condition. This phenomenon is due to an increase in the adhesive strength of the balsa wood sandwich composite as the curing pressure increases, thereby improving the compressive strength. Deboning and local buckling were observed on fracture surfaces of all balsa wood sandwich composite, but only global buckling was observed at honeycomb core sandwich composite.
Carbon Fiber Reinforced Plastics (CFRP) is an encouraging material for aerospace and automotive industries due to its light weight and high strength. Aerospace parts require precise dimensional tolerance and high machined surface quality for safety and reliability. Routing process is needed to produce satisfactory dimensional accuracy of CFRP parts. Machining defects of routing process are related to the cutting mode with respect to cutting angle and bonding strength between carbon fibers and polymer matrix. When the polymer matrix is transformed from polymer to amorphous state, bonding strength is declined. Therefore, cutting temperature is a critical parameter for CFRP machining process because glass transient temperature is relatively low. In this paper, cutting temperature was measured using thermal imaging camera. Machined surface roughness and maximum fiber pull-out depth were analyzed with respect to feed, spindle speed, and laminate structure.
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In this study, flexible fixtures and end effectors are conceptually designed for the holding of thin-walled carbon-fiber reinforced-plastic (CFRP) workpieces in machining processes. Firstly, the fixture scenarios and system requirements for the conceptual designs of flexible-fixture and core units are proposed, including the propounding of the workpiece-holding mechanism and the core-unit requirements. A ball-joint pneumatic system is determined as a locking mechanism of the flexible-fixture system for the machining of thin-walled components. Secondly, conceptual designs of the core units are suggested with the driven requirements from the fixture scenarios. A self-tilting mechanism and an end-effector return mechanism are also proposed. Finally, the prototypes of the core units are manufactured, and the workpiece-holding capacity of each prototype is measured.
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The recent development of core techniques in the IT industry can be summarized as a technical advancement for safety and convenience, and mechanical technology for being “eco-friendly” and lightweight. Under these circumstances, research of lightweight material has become attractive. In this study, CFRP (Carbon Fiber Reinforced Plastic) laminate specimens are subjected to a tensile test using the UTM(Universal Testing Machine, AG-IS 100 kN) to estimate their mechanical properties in terms of the Hole machining impact evaluation. The FEM (Finite Elements Method) analysis method is applied and the material properties obtained from basic experiments such as the Tensile test, the compressive test, and the shear test. CFRP materials properties from a previous study, as well as a finite element analysis program for Hole machining CFRP was compared with the experiments.
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