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Machining Composites Materials



Machining Composites Materials

J. Paulo Davim (Editor)

ISBN: 978-1-118-87514-8 October 2013 Wiley-ISTE 262 Pages

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In recent years, the application of composite materials has increased in various areas of science and technology due to their special properties, namely for use in the aircraft, automotive, defence, aerospace and other advanced industries. Machining composite materials is quite a complex task owing to its heterogenity, and to the fact that reinforcements are extremely abrasive. In modern engineering, high demands are placed on components made of composites in relation to their dimensional precision as well as their surface quality. Due to these potential applications, there is a great need to understand the questions associated with machining composite materials.

This book aims to provide the fundamentals and the recent advances in the machining of composite materials (polymers, metals and ceramics) for modern manufacturing engineering. The three parts of the book cover the machining of polymeric, metal and ceramic matrix composites.

This book can be used as a text book for the final year of an undergraduate engineering course or for those studying machining/composites at the postgraduate level. It can also serve as a useful work of reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals in composite technology and related industries.

Preface xi

Chapter 1. Mechanics and Modeling of Machining Polymer Matrix Composites Reinforced by Long Fibers 1
Liangchi ZHANG

1.1. Introduction 1

1.2. Orthogonal cutting 2

1.3. Cutting force modeling 13

1.4. Drilling 21

1.5. Abrasive machining 35

1.6. Concluding notes 35

1.7. References 36

Chapter 2. Machinability Aspects of Polymer Matrix Composites 39
Franck GIROT, Luis Norberto LÓPEZ DE LACALLE, Aitzol LAMIKIZ, Daniel ILIESCU and Mª Esther GUTIÉRREZ

2.1. The machining of polymer composites 40

2.2. Tools 41

2.3. Cutting mechanisms in composite materials 54

2.4. Composite material damage due to machining 65

2.5. Milling of composite materials 70

2.6. Turning of composite materials 101

2.7. Conclusions 106

2.8. Acknowledgments 107

2.9. References 107

Chapter 3. Drilling Technology 113
Alexandre M. ABRÃO, Juan C. CAMPOS RUBIO, Paulo E. FARIA and J. Paulo DAVIM

3.1. Introduction 113

3.2. Standard and special tools 117

3.3. Cutting parameters 123

3.4. Tool wear 125

3.5. Drilling forces 131

3.6. Surface integrity 140

3.7. Dimensional and geometric deviations 153

3.8. Conclusions 157

3.9. Acknowledgements 159

3.10. References 159

Chapter 4. Abrasive Water Jet Machining of Composites 167
François CÉNAC, Francis COLLOMBET, Michel DÉLÉRIS and Rédouane ZITOUNE.

4.1. Introduction 167

4.2. Brief history of AWJT 168

4.3. AWJ machining process 168

4.4. AWJ cutting process 171

4.5. Quality of the kerf 172

4.6. AWJ cutting of composite materials 173

4.7. Applications 176

4.8. Perspectives 178

4.9. AWJ milling of composite materials 178

4.10. References 180

Chapter 5. Machining Metal Matrix Composites 181
Alokesh PRAMANIK and Liangchi ZHANG

5.1. Introduction 181

5.2. Conventional machining 182

5.3. Non-conventional machining 190

5.4. Tool−workpiece interaction 195

5.5. Summary 203

5.6. References 203

Chapter 6. Machining Ceramic Matrix Composites 213
Mark J. JACKSON and Tamara NOVAKOV

6.1. Introduction 213

6.2. Electro-discharge machining of CMCs 213

6.3. Water jet machining of CMCs 226

6.4. Laser machining of CMCs 227

6.5. Ultrasonic machining of CMCs 234

6.6. Application of CMCs: cutting tool inserts 245

6.7. Review of various technologies for machining CMCs 251

6.8. References 253

List of Authors 257

Index 261

"This book should be very useful to anyone machining or cutting composite parts to final shape in order to avoid damaging expensive parts." (Materials World, 1 July 2011)

"Focusing on polymers, metals and ceramics, this title provides background and coverage of recent advances in machining composites in modern manufacturing engineering." (Materials World, 1 January 2011).