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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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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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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