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2021 | Buch

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Advances in Machining of Composite Materials

Conventional and Non-conventional Processes

herausgegeben von: Dr. Islam Shyha, Dr. Dehong Huo

Verlag: Springer International Publishing

Buchreihe : Engineering Materials

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

This book covers a wide range of conventional and non-conventional machining processes of various composite materials, including polymer and metallic-based composites, nanostructured composites and green/natural composites. It presents state-of-the-art academic work and industrial developments in material fabrication, machining, modelling and applications, together with current practices and requirements for producing high-quality composite components. There are also dedicated chapters on physical properties and fabrication techniques of different composite material groups. The book also has chapters on health and safety considerations when machining composite materials and recycling composite materials. The contributors present machining composite materials in terms of operating conditions; cutting tools; appropriate machines; and typical damage patterns following machining operations. This book serves as a useful reference for manufacturing engineers, production supervisors, tooling engineers, planning and application engineers, and machine tool designers. It can also benefit final-year undergraduate and postgraduate students, as it provides comprehensive information on the machining of composite materials to produce high-quality final components. The book chapters were authored by experienced academics and researchers from four continents and nine countries including Canada, China, Egypt, India, Malaysia, Portugal, Singapore, United Kingdom and the USA.

Inhaltsverzeichnis

Frontmatter

Introduction

Abstract

When two or more different materials are combined, the result is a composite. People think composite materials were discovered recently. However, surprisingly, composites were firstly used in around 1500 BC when ancient Egyptians and Mesopotamian settlers used a mixture of mud and straw to create healthy and durable buildings. Straw has also been used as reinforcement to ancient composite products including pottery and boats. Scientists successfully developed various types of plastics in the early 1900s. However, plastics alone cannot provide enough strength for some structural applications. Therefore, reinforcement was deemed essential to provide additional strength and rigidity; subsequently, composites entered a new era. In 1935, Owens Corning introduced the first glass fibre (fibreglass). Fibreglass, when combined with a plastic polymer, creates an incredibly strong structure that is also lightweight. This is believed to be the beginning of the fibre-reinforced polymer (FRP) composites industry.

Islam Shyha, Dehong Huo, J. Paulo Davim

Fibre Reinforced Polymer Composites

Abstract

Fibre reinforced polymer (FRP) composites are attractive engineering materials because they have excellent properties, such as high strength-to-weight, modulus-to-weight, magnetic and corrosion resistance. FRPs are formed by combining the fibres and polymer matrix, providing properties that could not be obtained from a single material component alone. Categories of fibre include carbon fibre, glass fibre, boron fibre, aramid fibre and others. The resin matrixes used are mainly thermosetting resin and thermoplastic resin. Besides, laminated and cylindrical FRPs are two common forms used in structural applications. Due to their excellent usability, FRPs have seen extensive applications in a wide range of industries including aerospace, aircraft, military, mobile phone, automobiles, infrastructure and sporting goods. Additionally, FRPs will be essential materials in many fields in the future.

Ben Wang, Hang Gao

Conventional Machining Processes of Fibre Reinforced Polymer Composites

Abstract

Although FRPs are usually fabricated to near net shapes after curing, post-machining operations are necessary to assure that the composite parts meet dimensional tolerance, surface quality and other functional requirements. Owing to the material’s unique anisotropic characteristics, it is a challenge to machine FRPs without machining damage. Machining damages can arise in each phase of the material, including matrix cracking, fibre fracture, fibre pull-out, fibre-matrix debonding and delamination. Orthogonal cutting is a common machining process for better understanding of the mechanisms of common processing methods. Traditional machining operations, such as turning, milling and drilling, are still the primary processing mode of FRPs. With considerations to processing demands and material performance of different composite materials, developing the corresponding special cutter is the key technology to prolong the cutter’s service life and improve processing quality.

Ben Wang, Hang Gao

Nonconventional Machining Processes of Fibre Reinforced Polymer Composites

Abstract

Driven by the need for lightweight and high-strength materials for parts and components in the aviation and automotive sectors, research activities aim to achieve these requirements exponentially. These research activities are not limited in material processing, testing and development, but also extended to the material’s machinability. This chapter provides a comprehensive introduction which includes cutting mechanisms and critical process variables when machining fibre-reinforced polymer (FRP) composites using nonconventional machining processes, namely abrasive waterjet machining (AWJM), laser beam machining (LBM) and electrical discharge machining (EDM). Besides, the effects of machining process parameters on machinability outputs are also discussed.

Ming Ming Wong Irina, Iskandar Bin Azmi Azwan

Modelling Machining of FRP Composites

Abstract

Machining of composite materials still represents a challenge in terms of controlling the process, especially to eliminate or minimise damage to the machined workpiece. Numerical models represent a powerful tool, usually used to investigate and optimize the process. For this reason, an overview of the state of the art of numerical techniques for simulating machining of composite materials at a macro-scale and micro-scale level is provided. Models based on the finite element method and mesh-free methods are discussed; advantages and drawbacks are highlighted. Finally, current models’ ability to predict chip morphology, chip formation mechanisms, machining force and damages in the ma-chined workpiece is discussed.

Alessandro Abena, Fadi Kahwash, Khamis Essa

Metal Matrix Composites

Abstract

The chapter introduces the various types of matrix and reinforcements used in metal matrix composites (MMCs) and gives an overview of the types of MMCs, namely fibre reinforced MMCs; particle reinforced MMCs and multi-layer laminates. Standard manufacturing processes for MMCs include Solid-State Processing Methods such as powder metallurgy, mechanical alloying, diffusion bonding and deformation processing, Liquid Processing Methods such as stir casting, melt infiltration, squeeze casting and melt deposition are also presented in Sect. 3. In addition, in situ processes and additive manufacturing of MMCs are also introduced. In Sect. 4, equations are provided to allow the prediction of the properties of MMCs such as density, modulus and strength. Strengthening mechanisms for particle reinforced composites are briefly explained in Sect. 5. A review of various mechanical properties of MMCs produced by different manufacturing techniques is provided in Sect. 6. Lastly, the chapter provides the use of MMCs in various industries.

Wai Leong Eugene Wong, Sankaranarayanan Seetharaman

Conventional Machining of Metal Matrix Composites

Abstract

This chapter provides an introduction to conventional machining of metal matrix composites (MMCs). The critical machining characteristics, namely chip formation mechanism, effects of cutting parameters, build-up edge, and tool wear with various types of cutting tool materials are discussed. In response to new developments on MMCs reinforced with nanoparticles, the state-of-the-art machining of both aluminium and magnetism-based nano-MMCs is presented, focusing on micromachining as lots of products and applications using nano-MMCs are expected in microscale.

Xiangyu Teng, Dehong Huo

Non-conventional Machining of Metal Matrix Composites

Abstract

The machining of monolithic materials such as metals and alloys is a well-established process and is used extensively in a wide range of applications in many sectors of the aerospace, medical and automotive industries. However, metal matrix composites (MMCs) are particularly challenging due to the differences in the chemical and physical properties of the hard reinforcement and the metal matrix. Non-conventional machining (NCM) is an excellent tool for the processing of advanced materials such as metal matrix composites. This chapter provides an overview on the machining of metal matrix composites using a range of non-traditional manufacturing techniques including laser processing, electrical discharge machining, waterjet machining and selected others. Productivity and surface integrity aspects such as roughness and delamination are reviewed and discussed. The advantages and disadvantages against conventional methods are also discussed in detail.

Justin Dunleavey, Sundar Marimuthu, Mohammad Antar

Finite Element Modelling of Machining of Metal Matrix Composites

Abstract

The fundamental material removal mechanism is central to understanding the machining process of metal matrix composites and improving such materials’ machinability. Numerical models have been used extensively in the investigation of the machining process. It offers many advantages over experimental methods, particularly for examining the micro-scale phenomena that are hard to observe through experiments. This chapter will focus on the most widely used modelling method—finite element (FE) modelling. It starts from an overview of FE modelling on machining of MMCs. Then the general finite element model formulation is introduced. Finally, a case study using FE modelling on the cutting mechanism of Mg-MMCs reinforced with micro-sized and nano-sized particles.

Xiangyu Teng, Dehong Huo, Islam Shyha

Drilling of Fibre Reinforced Polymers and Hybrid Stacked Materials

Abstract

Hole making represents the majority of the machining operations of composites and hybrid stacked aerospace-structures. Conventional drilling induced part defects, such as delamination of layers and thermal damage of the matrix, are of major economic and safety concerns for aerospace manufacturers. This chapter discusses selected emerging non-conventional processes for drilling of composites and hybrid stacks, which could effectively prevent the sources of drilling induced damage without compromising the process productivity. The discussion in this chapter has focused on process optimization based on understanding the mechanics of the process. Additionally, a new online cyber-physical adaptive control (CPAC) capability is presented, which demonstrates the maximization of tool life and process productivity while preserving the part quality based on integrated advanced process modeling and smart real-time tool wear detection.

Ahmed Sadek, Zhongde Shi, Mouhab Meshreki, Ireene Sultana, Helmi Attia

Ceramic Matrix Composites (CMCs)

Abstract

Ceramic matrix composites (CMCs) are a class of composite materials in which filler are incorporated within a ceramic matrix. As a result of filler addition to ceramic matrix, specific properties can be altered. There are various ways to manufacture ceramics and CMCs, mainly depending upon the filler material and the final application. One such property is a reduction in crack propagation. Although their constituents are brittle, CMCs have found their applications in the vast majority of the area, including space, refractories, energy storage, and automotive. This chapter considers classification and manufacturing CMCs. This chapter summarises state of the art for CMCs and their manufacturing techniques and lays the foundation for their micromachining.

Jibran Khaliq

Machining of Ceramic Matrix Composites

Abstract

Carbon fibre-reinforced ceramic matrix composites have many excellent physical and mechanical properties, such as high specific strength, hardness, and fracture toughness compared to their matrix, and they also possess good performance in wear, heat and ablation resistance and dimensional stability. They are an ideal choice for thermal protection and high-temperature structural materials. However, their characteristics of high hardness and abrasive nature make these materials difficult to machine, which limits their large-scale industrial application. This chapter reviews research on the machining of carbon fibre-reinforced ceramic matrix composites, including conventional and unconventional machining processes. The problems arising with various machining methods and possible solutions are discussed.

Jinguang Du, Haizhen Zhang, Yongmiao Geng, Wuyi Ming, Wenbin He, Jun Ma, Yang Cao, Xiaoke Li, Kun Liu

Nano-structured Polymer-Based Composites

Abstract

Nano-structured polymer-based composites have gained much importance in recent years due to their improved and excellent properties compared to their bulk-sized equivalents. In nanostructured polymer composites, nano-sized particles are added to the matrix material as nanoparticles have a too high surface to volume ratio, resulting in improved composites’ overall properties. In this chapter, various nano-structured polymer-based composites are discussed based on their suitable applications. The properties of nano-structured polymer-based composites such as thermal, mechanical, flame retardancy, electrical and optical properties, barrier properties, anticorrosive properties, and adsorption behaviour and factors affecting the properties are discussed. This chapter also presents the different manufacturing techniques of nano-structured polymer-based composites.

Abhishek Gaikwad, Kishore Debnath, Manoj Kumar Gupta

Machining of Nano-Structured Polymer Composites

Abstract

Nanocomposites have been discovered and researched for over 60 years due to their advanced characteristics such as mechanical, thermal and electrical properties compared to other materials (i.e., metals, ceramics and alloys). Among the most functional nanomaterials, polymer nanocomposites have found many industrial applications, especially as structural materials. Although near-net-shape (NNS) manufacturing processes could be employed to fabricate these materials, higher qualities in terms of machine surface and dimensional accuracy, especially in complex features are still required since they are crucial requirements in modern manufacturing. Therefore, machining seems to be an inevitable process and have found huge potential to generate high-precision products. However, machining of polymer nanocomposites is more severe than that of other materials due to their anisotropic, heterogeneous structure and high mechanical properties (i.e., high abrasiveness, fracture toughness, tensile strength) of their reinforcing constituents. These factors could result in low machined surface quality, typical damages introduced into the machined surfaces and tool wear acceleration. Therefore, investigation on machining behaviours of these polymer nanocomposites is necessary to provide suitable cutting conditions. This chapter addresses these materials’ machinability when using major machining processes, including conventional, non-conventional, and micromachining.

Bao Le, Islam Shyha, Dehong Huo

Green, Natural Fibre and Hybrid Composites

Abstract

The use of composite materials has seen a surge in many applications such as aerospace, automotive, marine, and medical and sports equipment. The increasing demand for more sustainable and renewable materials has increased natural fibres’ interest as a reinforcement for composite materials. Natural fibres are environmentally friendly, but they also have high specific properties due to their lightweight. This chapter provides an overview of natural fibre and hybrid composites, the types of fibre used, their extraction methods, properties, and microstructure. Moreover, a special section is dedicated to the conversion techniques from fibres to preforms, and the manufacturing methods from preforms to final composites. At the end of the chapter, there is a comprehensive list of all commercial applications of natural fibre composites compiled from JEC Composites Market news from 2011 to 2019, with a discussion on the prospects of adopting natural fibre composites in the industry.

Mohamad Midani, Ahmed H. Hassanin

Machining of Bio-composites

Abstract

Due to growing environmental concerns, the engineers and researchers have shifted to using renewable resources to replace many non-renewable, conventional materials like metals and synthetic fibres. Natural fibre-reinforced polymer composites (bio-composites) are usually human-made materials that have gained huge attention in various fields of engineering applications. However, the difficulties in the secondary manufacturing of these composites due to the anisotropic and heterogeneous nature create a barrier in the large-scale production of bio-composites products. This chapter deals with various machining operations associated with natural fibre-reinforced composites. The challenges faced during the machining of natural fibre-reinforced composites have been summarised. Different ways of assisting the quality and improvement of the machined surface have been discussed.

Mridusmita Roy Choudhury, Kishore Debnath

Grinding and Abrasive Machining of Composite Materials

Abstract

The grinding or abrasive machining of composite materials is a complex system that relies on the use of hard materials such as alumina and diamond to achieve precisely machined functional surfaces. This chapter focuses on the grinding of polymer matrix composites (PMCs), metal matrix composites (MMCs), and ceramic matrix composites (CMCs) and explains how abrasive grain and bonding characteristics affect the grindability of fibrous materials surrounded by a binder. The chapter reviews the current literature surrounding the specification of abrasive products in use for shaping PMCs, MMCs and CMCs and provides an insight into the future specifications of abrasive grains and bonded products for grinding increasingly complex composite materials.

Mark J. Jackson, Martin J. Toward

Cutting Tools for Machining Composites

Abstract

The machining of composite components finds lot of challenges due to the abrasive nature of the fibres used. The problems such as delamination, fibre pull-out and resin degradation which may be encountered during machining of workpiece and deciding its quality characteristics. Also, the tool wear is a major concern which has to be considered in controlling tooling cost and impact final product cost. Therefore, it is necessary to appropriately select the suitable cutting tool which is expected to cause minimum damages to workpieces. This chapter discusses the cutting tools used when machining (mainly drilling and milling) polymer matrix composites (PMC). The chapter will also discuss cutting conditions, cutting tool materials, cutting tool geometry and coatings. The machinability characteristics due to the effect of cutting parameters and tool materials/geometries during drilling various composite materials will be compared. High speed edge trimming of carbon fibre reinforced polymer (CFRP) materials using fluted and router tools is also discussed to determine the effect of tool geometry and tool coating materials on surface roughness of machined surfaces and the tool wear. This chapter also discusses the cutting tools for machining of metal matrix composites (MMC) and ceramic matrix composites (CMC).

Rangasamy Prakash, Vijayan Krishnaraj

Health and Safety Considerations in Machining of Composites

Abstract

Machining of composite creates dust particles that can enter the human respiratory system and reach the bloodstream. Several toxicology studies depict the harmful effect of composite dust on animals. This chapter briefly reviews the detrimental impacts of composite dust, exposure limit of dust, and methods to collect and control dust generation. The relationship of machining parameters to dust formation is discussed based on the limited existing literature. A safe dust collection and real-time dust analysis system based on the isokinetic sampling technique is illustrated in this chapter.

Mamidala Ramulu, Mohammad Sayem Bin Abdullah

Recycling of Composite Materials

Abstract

Usage of composite material is rising across various sectors such as automotive, wind energy and aerospace. Compared to metal matrix composites (MMCs) and ceramic matrix composites (CMCs), thermoset based polymer matrix composites (PMCs) dominate the market. The heterogeneous nature of composite materials and cross-linked nature of the thermoset matrix make recycling to be difficult. Research and development in recycling such material is required. In this chapter, composite recycling techniques are explained and reviewed from the aspect of energy consumption and mechanical properties of the recyclate. Possible reuse applications are suggested. This chapter highlights the concept of composite material sustainability and circular economy.

Norshah Aizat Shuaib, Al Amin Mohamed Sultan, Sikiru Oluwarotimi Ismail, Abdullah Abdul Samat, Nur’ain Wahidah Ya Omar, Azwan Iskandar Azmi, Paul Tarisai Mativenga

Titel: Advances in Machining of Composite Materials
herausgegeben von: Dr. Islam Shyha
Dr. Dehong Huo
Verlag: Springer International Publishing
Electronic ISBN: 978-3-030-71438-3
Print ISBN: 978-3-030-71437-6
DOI: https://doi.org/10.1007/978-3-030-71438-3

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