Advances in Machining of Composite Materials: Conventional and Non-conventional Processes (Engineering Materials)

✍ Scribed by Islam Shyha (editor), Dehong Huo (editor)

• Publisher: Springer
• Year: 2021
• Tongue: English
• Leaves: 547
• Edition: 1st ed. 2021
• Category: Library

✦ Synopsis

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.

✦ Table of Contents

Contents
Introduction
1 Composite Materials
2 Classifications of Composite Materials
2.1 Classification Based on the Matrix
2.2 Classification Based on Reinforcement Size
3 Machining of Composite Materials
4 Structure of the Book
References
Fibre Reinforced Polymer Composites
1 Introduction
2 Classification of Polymer Matrix Composites
2.1 Glass Fibre
2.2 Carbon Fibre
2.3 Aramid Fibre
2.4 Boron Fibre
2.5 Resin Matrix
3 Properties of FRP Composites
4 Manufacturing Techniques of FRP Composites
4.1 Laminated Composites
4.2 Cylindrical Structures
5 Applications of FRP Composites
5.1 Aircraft and Aerospace Applications
5.2 Military Applications
5.3 Mobile Phone Applications
5.4 Automotive Applications
5.5 Infrastructure Applications
5.6 Sporting Goods Applications
6 Review Questions
References
Conventional Machining Processes of Fibre Reinforced Polymer Composites
1 Introduction
2 Characteristics of Conventional Machining of FRPs
3 Removal Mechanisms
3.1 Influence of Fibre Direction
3.2 Influence of Cutting Angle of the Cutter
4 Classification of Conventional Machining Processes of FRPs
4.1 Turning Processes
4.2 Drilling Processes
4.3 Milling Processes
5 Cutting Tools for Conventional Machining of FRPs
6 Review Questions
References
Nonconventional Machining Processes of Fibre Reinforced Polymer Composites
1 Introduction
2 Overview of Nonconventional Machining Process for FRPs
3 Classification of Nonconventional Machining Processes of FRPs
4 Abrasive Waterjet Machining (AWJM)
4.1 Material Removal Mechanisms of Abrasive Waterjet Machining
4.2 Abrasive Waterjet Machining Characteristics of FRPs
5 Laser Beam Machining (LBM)
5.1 Material Removal Mechanisms of Laser Beam Machining
5.2 Features of Laser Beam Machining of FRPs
6 Electrical Discharge Machining (EDM)
6.1 Material Removal Mechanisms of Electrical Discharge Machining
6.2 Features of Electrical Discharge Machining of FRPs
7 Summary
8 Review Questions
References
Modelling Machining of FRP Composites
1 Introduction
2 Chip Formation Mechanisms of FRP Composites
3 Classification of Numerical Modelling Techniques
4 Finite Element Modelling When Cutting FRP Composites
4.1 Macro-Mechanical Approach
4.2 Micro-Mechanical and Mesoscale Approaches
5 Mesh-Free Modelling When Cutting FRP Composites
5.1 Smoothed Particle Hydrodynamics
5.2 Discrete Element Method
5.3 Element-Free Galerkin Method
6 Summary
7 Review Questions
References
Metal Matrix Composites
1 Introduction
1.1 Matrix
1.2 Reinforcements
1.3 Interfaces
2 Classification of MMCs
2.1 Fibre Reinforced MMCs
2.2 Particle Reinforced Composites
2.3 Multi-layer Laminate Composites
3 Manufacturing Techniques of MMCs
3.1 Solid-State Processing Methods
3.2 Liquid Processing Methods
3.3 In Situ Processes
3.4 Additive Manufacturing
4 Predicting Properties of MMCs
4.1 Volume and Weight Fractions
4.2 Density
4.3 Coefficient of Thermal Expansion (CTE)
4.4 Modulus of Elasticity
4.5 Tensile Strength
5 Strengthening Mechanisms
5.1 Dislocation Strengthening
5.2 Grain Refinement Strengthening
5.3 Orowan Strengthening
6 Review of Mechanical Properties of Developed MMCs
7 Application of MMCs
8 Review Questions
References
Conventional Machining of Metal Matrix Composites
1 Introduction
2 Chip Formation Mechanism
3 Effects of Cutting Parameters and Built-up Edge
3.1 Effects of Cutting Parameters
3.2 Built-up Edge
4 Cutting Tools Wear for Machining of MMCs
4.1 Uncoated Carbide Tools
4.2 Coated Carbide Tools
4.3 Cubic Boron Nitride Tools
4.4 Polycrystalline Diamond Tools
5 Micromachining of MMCs
5.1 Size Effect in Micromachining
5.2 State-of-the-Art of Micromachining of Metal-Based Nanocomposites
5.3 Tool Wear Mechanism in Micromachining of MMCs
6 Summary
7 Review Questions
References
Non-conventional Machining of Metal Matrix Composites
1 Introduction
1.1 MMC Material and Machining Characteristics
1.2 Non-conventional Machining of Composites
2 Laser Processing
2.1 Laser Drilling of Aluminium Metal Matrix Composites
2.2 Water-Jet Guided Laser Drilling of Aluminium Metal Matrix Composites
3 Electrical Discharge Machining
3.1 EDM of Particulate Reinforced Metals
3.2 Die-Sink EDM of Particle Reinforced Metals
3.3 EDM of Fibre Reinforced Metals
4 Abrasive Waterjet Machining
4.1 Material Removal Mechanism
4.2 Particle Reinforced Metal Matrix Composites
4.3 Fibre Reinforced Metal Matrix Composites
5 Electrochemical Machining
5.1 Material Removal Mechanism
5.2 Hybridization
6 Ultrasonic and Vibration Assisted Machining
6.1 Ultrasonically Assisted Machining of MMCs
7 Summary
8 Review Questions
References
Finite Element Modelling of Machining of Metal Matrix Composites
1 Introduction
2 Review of FE Modelling on Machining of MMCs
3 Overview of Finite Element Model Formulation
3.1 Materials Constitutive Model Formulation
3.2 Fracture Criterion
3.3 Friction Between Tool-Chip Interface
4 FE Modelling on the Cutting Mechanism of Nano-Particles MMCs
4.1 Modelling Procedures
4.2 Chip Formation Process Analysis
4.3 Effect of Uncut Chip Thickness
5 Comparison Between Micro-Sized and Nano-Sized Particles Reinforced MMCs
5.1 Von-Mises Stress Distribution in the Cutting Area
5.2 Tool-Particles Interaction
5.3 Chip Formation Process
5.4 Machined Surface Morphology
6 Review Questions
References
Drilling of Fibre Reinforced Polymers and Hybrid Stacked Materials
1 Introduction
2 Conventional Drilling of Hybrid Stacks
3 Vibration-Assisted Drilling of FRPs and Hybrid Stacks
3.1 Drilling Forces in Vibration-Assisted Drilling (VAD)
3.2 The Thermal Aspect of Vibration-Assisted Drilling (VAD)
3.3 Hole Quality and Surface Integrity in VAD
4 Orbital Drilling (OD) of FRPs and Hybrid Stacks
4.1 Cutting Forces in Orbital Drilling (OD)
4.2 The Thermal Aspect of Orbital Drilling (OD)
4.3 Hole Quality and Surface Finish in OD
5 Orbital Drilling of CFRPs with Super Abrasive Tools
5.1 Tool Performance and Hole Surface Quality
5.2 Overcoming the Hole Surface Roughness Challenge
6 Predictive Model-Based Adaptive Drilling of Composite/Metal Stacks
7 Review Questions
References
Ceramic Matrix Composites (CMCs)
1 Introduction
2 Classification of Ceramic Matrix Composites
2.1 Micro Composites
2.2 Nanocomposites
3 Properties of Ceramic Matrix Micro Composites
3.1 Mechanical Properties
3.2 Electrical Properties
3.3 Thermal Properties
3.4 Corrosion Resistance
4 Properties of Ceramics Matrix Nanocomposites
5 Manufacturing of Ceramics Matrix Composites (CMCs)
5.1 Manufacturing of CMC Micro Composites (Powder Synthesis Methods)
5.2 Manufacturing of CMC Nanocomposites
6 Machining of CMCs
7 Application of CMCs
7.1 Space Application
7.2 Brake Disk
7.3 Bearings
7.4 Manufacturing
7.5 Magnetic Application
8 Review Questions
References
Machining of Ceramic Matrix Composites
1 Introduction
2 Conventional and Unconventional Machining of Ceramic Matrix Composites
2.1 Conventional Machining
2.2 Unconventional Machining
3 Discussion
4 Conclusions
5 Review Questions
References
Nano-structured Polymer-Based Composites
1 Introduction
2 Classification of Nanocomposites
2.1 Polymer-Matrix Nanocomposites
3 Properties of Composites Reinforced with Nanofillers
3.1 Mechanical Properties
3.2 Thermal Properties
3.3 Flame Retardancy
3.4 Electrical and Optical Properties
3.5 Barrier Properties
3.6 Anticorrosive Properties
3.7 Adsorption Behaviour
4 Manufacturing Techniques of Nano-Composites
5 Applications of Nanocomposites
6 Review Questions
References
Machining of Nano-Structured Polymer Composites
1 Introduction
2 Machining of Polymer Nanocomposites
2.1 Polymer Nanocomposites as High-Performance Engineering Materials
2.2 Milling of Polymer Nanocomposites
2.3 Drilling of Polymer Nanocomposites
2.4 Turning of Polymer Nanocomposites
3 Mechanical Micromachining of Polymer Nanocomposites
3.1 Removal Mechanisms of Micromachining and Differences from Macro-Scale
3.2 Micromachining of Polymer Nanocomposites
3.3 Tool Wear in Micromachining of Polymer Nanocomposites
4 Non-Conventional Micromachining of Polymer Nanocomposites
5 Review Questions
References
Green, Natural Fibre and Hybrid Composites
1 Introduction
2 Cellulosic Fibres
2.1 World Consumption of Cellulosic Fibres
2.2 The Microstrucssssture of Cellulosic Fibres
2.3 Cellulosic Fibres Classification
2.4 Cellulosic Fibres Extraction
2.5 Cellulosic Fibres Properties
3 Manufacturing Techniques of Natural Fibre and Hybrid Composites
3.1 Preform Manufacturing
3.2 Manufacturing Techniques
4 Applications of Natural Fibre and Hybrid Composites
4.1 Barriers to the Diffusion of NFC
4.2 Commercial Applications of NFC
5 Review Questions
References
Machining of Bio-composites
1 Introduction
2 Bio-composites
3 Machining of Bio-composites
4 Challenges During Machining of Bio-composites
4.1 Delamination
4.2 Surface Roughness
4.3 Other Machining Defects
4.4 Machining Induced Forces
4.5 Machining Induced Temperature
5 Research to Study Machining Behaviour of Bio-composites
6 Effect of Process Parameters on Machining Quality
6.1 Effect of Feed
6.2 Effect of Spindle Speed
6.3 Effect of Depth of Cut
6.4 Effect of Cutting Tool
6.5 Effect of Nature of Reinforced Fibres
7 Conclusions
8 Review Questions
References
Grinding and Abrasive Machining of Composite Materials
1 Introduction
2 Characteristics of Grinding Grains and Grinding Tools for Composite Materials
2.1 Shape
2.2 Abrasive Wear
2.3 Abrasive Grain Fracture Toughness
2.4 Medium Hardness Abrasive Grains
2.5 High Hardness Abrasive Grains
2.6 Grinding Products for Composite Materials
3 Grinding of Composite Materials
3.1 Polymer Matrix Composites (PMCs)
3.2 Metal Matrix Composites (MMCs)
3.3 Ceramic Matrix Composites (CMCs)
4 Conclusion
5 Review Questions
References
Cutting Tools for Machining Composites
1 Introduction
2 Classification of Cutting Tools
3 Tool Requirements for Machining Polymer Matrix Composites
3.1 Introduction
3.2 Cutting Tools for Drilling of Polymer Matrix Composites
3.3 Cutting Tools for Milling (Edge Trimming) of CFRP Composites
4 Cutting Tools for Machining Metal Matrix Composites
4.1 Introduction
4.2 Cutting Tools
5 Cutting Tools for Machining Ceramic Matrix Composites
6 Review Questions
References
Health and Safety Considerations in Machining of Composites
1 Introduction
2 Dust Generation in Composite Machining and Health Issues
3 Exposure Limit and Distribution of Dust Particles
4 Dust in Relation to Machining Processes and Parameters
5 Dust Collection and Characterization Techniques
6 Hazard Mitigation Approaches
7 Summary
8 Review Questions
References
Recycling of Composite Materials
1 Introduction
2 Composite Waste
3 Drivers for Composite Recycling
3.1 Legislation and Policies
3.2 Embodied Energy and Cost of Virgin Materials Production
4 Challenges in Composite Recycling
5 Composite Recycling Methods
5.1 Composite Recycling Process Chain
5.2 Combustion
5.3 Mechanical Recycling
5.4 Thermal Recycling
5.5 Chemical Recycling
5.6 Other Recycling Methods
6 Environmental Impact of Composite Recycling Processes
7 Quality of Recycled Fibre and New Composite Product
8 Application of Composite Recyclate
8.1 Automobile Sector
8.2 Aerospace Industry
8.3 Wind Energy
8.4 Electrical and Electronics Industry
8.5 Other Applications
9 Conclusions
10 Review Questions
References