Elgnemi Tarek-Shaban-Mohamed, Jun Martin Byung-Guk, Songmene Victor, Samuel Agnes Marie
Department of Mechanical Engineering, École de Technologie Supérieure (ÉTS), Montreal, QC H3C 1K3, Canada.
Department of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA.
Materials (Basel). 2021 Apr 20;14(8):2062. doi: 10.3390/ma14082062.
Carbon fiber reinforced polymers (CFRPs) have found diverse applications in the automotive, space engineering, sporting goods, medical and military sectors. CFRP parts require limited machining such as detouring, milling and drilling to produce the shapes used, or for assembly purposes. Problems encountered while machining CFRP include poor tool performance, dust emission, poor part edge quality and delamination. The use of oil-based metalworking fluid could help improve the machining performance for this composite, but the resulting humidity would deteriorate the structural integrity of the parts. In this work the performance of an oil-in-water emulsion, obtained using ultrasonic atomization but no surfactant, is examined during the milling of CFRP in terms of fiber orientation and milling feed rate. The performance of wet milling is compared with that of a dry milling process. The tool displacement-fiber orientation angles (TFOA) tested are 0°, 30°, 45°, 60°, and 90°. The output responses analyzed were cutting force, delamination, and tool wear. Using atomized vegetable oil helps in significantly reducing the cutting force, tool wear, and fiber delamination as compared to the dry milling condition. The machining performance was also strongly influenced by fiber orientation. The interactions between the fiber orientation, the machining parameters and the tested vegetable oil-based fluid could help in selecting appropriate cutting parameters and thus improve the machined part quality and productivity.
碳纤维增强聚合物（CFRP）已在汽车、太空工程、体育用品、医疗和军事领域得到广泛应用。CFRP部件只需进行有限的加工，如迂回加工、铣削和钻孔，以制造所需形状或用于组装。加工CFRP时遇到的问题包括刀具性能差、粉尘排放、部件边缘质量差和分层。使用油基金属加工液有助于提高这种复合材料的加工性能，但产生的湿度会降低部件的结构完整性。在这项工作中，研究了一种通过超声雾化但不使用表面活性剂获得的水包油乳液在CFRP铣削过程中纤维取向和铣削进给速率方面的性能。将湿铣削的性能与干铣削工艺的性能进行了比较。测试的刀具位移-纤维取向角（TFOA）为0°、30°、45°、60°和90°。分析的输出响应包括切削力、分层和刀具磨损。与干铣削条件相比，使用雾化植物油有助于显著降低切削力、刀具磨损和纤维分层。加工性能也受到纤维取向的强烈影响。纤维取向、加工参数和测试的植物油基流体之间的相互作用有助于选择合适的切削参数，从而提高加工部件的质量和生产率。
