Machining of Polymer Composites

320 Pages·2009·7.519 MB·English

by  Jamal Ahmad (auth.)

Machining of Polymer Composites
Jamal Y. Sheikh-Ahmad
Machining of Polymer
Composites
123
JamalY.Sheikh-Ahmad
ThePetroleumInstitute
DepartmentofMechanicalEngineering
AbuDhabi
UnitedArabEmirates
ISBN978-0-387-35539-9 e-ISBN978-0-387-68619-6
DOOOO I:10.1007/978-0-387-68619-6
LibraryofCongressControlNumber:2008932279
(cid:2)c 2009SpringerScience+BusinessMedia,LLC
Allrights reserved.Thisworkmaynotbetranslated orcopiedinwholeorinpartwithoutthewritten
permissionofthepublisher(SpringerScience+BusinessMedia,LLC,233SpringStreet,NewYork,NY
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withanyformofinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar
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notidentifiedassuch,isnottobetakenasanexpressionofopinionastowhetherornottheyaresubject
toproprietaryrights.
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Thisworkis dedicatedtomy family,who
stoodbymy sideallthetime:mywifeManal
andmychildrenIman,Sahar,Abdurrahman,
andAyah.
Preface
Theideaforwritingabookonmachiningfiber-reinforcedpolymer(FRP)compos-
itescameaboutduringthetimeItaughtagraduatecourseonthesubjectatWichita
StateUniversity.Preparinglecturenotesandmaterialforthecoursewasandstillisa
laboriousandpainstakingtaskbecauseofthelackofcompletebooksandreferences
onthesubject.ThemachiningofFRPcompositesisarelativelynewpractice,and
unlike the well-established practicesof metal machining,it is still in the develop-
mentstages.Despitethefactthatampleresearchworkhasbeenpublishedinthepast
threedecades,thereexistsnosinglesourcethatprovidesacomprehensivetreatment
ofthesubjectfromfundamentalandpracticalpointsofview.Therefore,aneedfor
suchabookexists,andthiscurrentbookisperhapsthefirstcompilationofitskind
onthesubject.
This book addresses both the theoretical foundation and practical aspects of
machiningFRPcomposites.Abriefintroductiontocompositematerialsisprovided
inChap.1.Thisisnecessarytofamiliarizereaderswhoarenewtothesubjectwith
theterminology,technology,andmanufacturingaspectsofpolymercomposites.The
sectiononpropertiesofcompositesattheendofthischapterisverybriefandbyno
meansisafairtreatmentofthisverycomplicatedsubject.Itsinclusionisnecessary
for completeness, so that the reader would appreciate the complexity of the sub-
ject. Chapter 2 providesa brief synopsis of machining kinematics. This treatment
is necessaryfor anyonewhointendsto engagein machiningstudies, whetherit is
for metals or composites. Chapter 3 covers the fundamental concept of mechan-
ics of chip formation from the experimentaland analytical perspectives. Much of
thetechniquesdiscussedinthischapterhavebeenimportedfromestablishedmetal
machiningtradition.Acaseinpointistheapplicationofsingleshearplanetheory
totheorthogonalmachiningoffiber-reinforcedcomposites.Therefore,greateffort
isspentinexplainingthesimilaritiesandcontrastsbetweenmachiningmetalsand
composites and the limitations of metal machining theories in this regard. Chap-
ter4discussesthephenomenaoftoolwearandprovidesanalysisoftoolmaterials
and tool wear mechanisms in machining FRP composites. Once again the differ-
encesintoolingrequirementsforcompositesandmetalsmachiningareconsidered.
Chapters 5 and 6 discuss the machinability of FRP composites by traditional and
vii
viii Preface
nontraditionalmethods,respectively.Theseincludeturning,milling,drilling,abra-
sive,abrasivewaterjet,andlasermachining.Recommendedindustrialpracticesand
tips are highlighted whenever possible. Finally, Chap. 7 discusses the important
issueofhealthandsafetyinmachiningFRPcomposites.Thischapterfamiliarizes
thereaderswiththehealthhazardsinvolvedinmachiningandsomeofthecurrent
standardssetbyappropriateauthoritiestodealwiththesehazards.
This book should serve as a valuable reference for those engaged in research
andformanufacturinganddesign engineerswho areengagedin processselection
anddesignofcuttingtoolsformachiningFRPcomposites.Italsoservesasacom-
plete and comprehensive textbook for one semester course on the subject at the
graduateandupperundergraduatelevelsinmanufacturing,mechanical,ormaterials
engineering.
ItsmypleasuretoacknowledgemanyofmygraduatestudentsatWichita State
University who contributed directly or indirectly to this book. Many of the refer-
encesIhaveusedinpreparingtheChaps.3–6werecollectedandreviewedbymy
studentsasapartoftheirresearchworkorasarequiredassignmentforthecourseon
machiningcomposites.Severalstudents,whosenamesappearinthereferenceslists,
haveprovidednecessaryexperimentalresultsincludedinthebook.Myappreciation
is also extended to several colleagues from academia and industry who reviewed
parts of the manuscriptand providedvaluable feedback.Finally, a special note of
thanksisduetomyeditorsSteveElliotandAngelaDePinafortheirindispensable
assistanceinpreparingthemanuscript.
AbuDhabi,UAE JamalY.Sheikh-Ahmad
Contents
1 IntroductiontoPolymerComposites ............................. 1
1.1 DefinitionsandClassification ................................ 2
1.2 AdvantagesandLimitations.................................. 3
1.3 Applications............................................... 5
1.4 ConstituentMaterials ....................................... 7
1.4.1 PolymerMatrices.................................... 8
1.4.2 Reinforcement ...................................... 12
1.4.3 CoreMaterial ....................................... 16
1.5 MaterialFormsandManufacturing............................ 16
1.5.1 ContinuousReinforcementForms ...................... 17
1.5.2 MoldingCompounds................................. 18
1.5.3 PrepregLayupandAutoclaveProcessing ................ 20
1.5.4 FilamentWinding.................................... 21
1.5.5 Pultrusion .......................................... 23
1.5.6 CompressionMolding ................................ 23
1.5.7 LiquidMolding...................................... 24
1.6 PropertiesofComposites .................................... 26
1.6.1 Density ............................................ 26
1.6.2 ElasticProperties .................................... 28
1.6.3 ThermalProperties................................... 29
1.6.4 MultiplyLaminates .................................. 30
1.7 Summary ................................................. 31
ReviewQuestionsandProblems................................... 33
References..................................................... 34
2 ConventionalMachiningOperations ............................. 37
2.1 RequirementsforMachiningFRPs ............................ 38
2.2 Turning................................................... 39
2.3 SinglePointCuttingTools ................................... 41
2.4 MillingandTrimming....................................... 42
2.5 Drilling................................................... 48
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x Contents
2.6 AbrasiveCutting ........................................... 51
2.7 SurfaceFinish ............................................. 55
2.8 Summary ................................................. 59
ReviewQuestionsandProblems................................... 60
References..................................................... 62
3 MechanicsofChipFormation ................................... 63
3.1 FundamentalConsiderations ................................. 64
3.1.1 OrthogonalMachining................................ 65
3.2 MachiningofPolymers...................................... 71
3.3 MachiningofUnidirectionalFRPS............................ 73
3.3.1 ChipFormationModes ............................... 73
3.3.2 CuttingForces....................................... 81
3.4 MachiningofMultidirectionalLaminates ...................... 89
3.4.1 ChipFormation...................................... 90
3.4.2 CuttingForces....................................... 90
3.5 ModelingoftheChipFormationProcess....................... 91
3.5.1 ShearPlaneModels .................................. 91
3.5.2 MechanicsModelofZhangetal.[20]................... 97
3.5.3 MechanisticModeling................................100
3.6 Summary .................................................104
ReviewQuestionsandProblems...................................106
References.....................................................109
4 ToolMaterialsandToolWear ...................................111
4.1 ToolMaterialsforMachiningFRPs ...........................111
4.1.1 CementedTungstenCarbides ..........................114
4.1.2 CoatedCarbides .....................................115
4.1.3 Ceramics ...........................................116
4.1.4 PolycrystallineDiamond..............................117
4.1.5 PolycrystallineCubicBoronNitride ....................118
4.1.6 DiamondCoatedCarbides.............................118
4.1.7 FutureOutlook ......................................119
4.2 ToolWear.................................................121
4.2.1 TypesofToolWear ..................................122
4.2.2 MeasurementofWear ................................123
4.2.3 ToolWearMechanisms ...............................124
4.2.4 ToolLife ...........................................133
4.3 Summary .................................................137
ReviewQuestionsandProblems...................................138
References.....................................................140
Contents xi
5 ConventionalMachiningofFRPs ................................143
5.1 MachinabilityofFRPs ......................................143
5.2 TurningofFRPs ...........................................145
5.2.1 FiberOrientationinTurning ...........................145
5.2.2 ToolWearinTurningofFRPs .........................146
5.2.3 CuttingForcesandSpecificCuttingEnergy ..............151
5.2.4 CuttingTemperatures.................................154
5.2.5 MachiningQuality ...................................157
5.3 MillingandTrimmingofFRPs ...............................160
5.3.1 FiberOrientationinMillingUnidirectionalFRPs .........161
5.3.2 ToolWear ..........................................162
5.3.3 CuttingForcesandSpecificCuttingEnergy ..............167
5.3.4 MachiningQuality ...................................177
5.3.5 RecommendedPractices ..............................183
5.4 DrillingofFRPs ...........................................187
5.4.1 FiberOrientationinDrilling ...........................188
5.4.2 DrillingThrustForceandTorque.......................189
5.4.3 CuttingTemperatures.................................196
5.4.4 MachiningQuality ...................................197
5.4.5 MechanicsofDelamination............................202
5.4.6 RecommendedPractices ..............................208
5.5 AbrasiveMachiningandGrinding ............................210
5.5.1 AbrasiveMachining..................................211
5.5.2 Grinding ...........................................216
5.6 Summary .................................................226
5.6.1 Turning ............................................227
5.6.2 MillingandTrimming ................................227
5.6.3 Drilling ............................................228
5.6.4 AbrasiveMachiningandGrinding ......................228
ReviewQuestionsandProblems...................................229
References.....................................................232
6 NontraditionalMachiningofFRPs...............................237
6.1 AbrasiveWaterjetMachining.................................237
6.1.1 TechnologyOverview ................................238
6.1.2 MaterialRemovalMechanisms.........................242
6.1.3 AWJMachiningCharacteristicsofFRPS ................246
6.1.4 ModelingofAWJCutting .............................256
6.2 LaserMachining ...........................................260
6.2.1 TechnologyOverview ................................261
6.2.2 MechanismsofMaterialRemoval ......................264
6.2.3 LaserMachiningCharacteristicsofFRPS................265
6.2.4 ModelingandAnalysis ...............................273
6.3 ElectricalDischargeMachining...............................276
6.3.1 TechnologyOverview ................................277
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6.3.2 MaterialRemovalMechanisms.........................279
6.3.3 EDMCharacteristicsofFRPS .........................280
6.4 Summary .................................................285
6.4.1 AWJMachining .....................................285
6.4.2 LaserMachining.....................................286
6.4.3 EDM ..............................................287
ReviewQuestionsandProblems...................................287
References.....................................................289
7 HealthandSafetyAspectsinMachiningFRPs ....................293
7.1 HazardSourcesandRoutesofExposure .......................294
7.1.1 MatrixMaterial......................................296
7.1.2 ReinforcementFibers.................................297
7.2 DustGenerationinDryMachining............................298
7.3 AerosolEmissionsinLaserMachining ........................300
7.4 WorkplaceControls.........................................302
7.4.1 AdministrativeControls...............................302
7.4.2 EngineeringControls.................................303
7.4.3 PersonalProtectiveEquipment.........................304
7.4.4 MachineToolHealth .................................304
7.5 Summary .................................................304
References.....................................................306
Index .............................................................309