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Machining of Composite Materials by Ultrasonic Assistance

Marcel Kuruc

Advances in Science and Technology. Research Journal

2020

Vol. 14, no 2

140--144

A lot of studies are focused on decreasing the weight of the manufactured components and increasing their mechanical properties or achieving additional unique properties. One of the results of their effort is a composite material. This kind of material consists of two phases – matrix and reinforcing phase. This unique combination of phases causes the superior properties of the composite material. However, since the material properties of the matrix differ from the material properties of the reinforcing material, certain difficulties during machining are caused. These difficulties include: delamination of the machined composite and reduced tool life. Those facts motivate other studies to investigate the machinability of the composite materials. A few possibilities on how to improve the machining process during the machining of composite materials were described. For example, Seco Tools Company started with developing a new shape of the cutting tools; DMG Mori Company successfully implemented the assistance of the ultrasound into the milling process and therefore achieved the enhanced machinability od the materials; the scientists from the Stan-ford University developed a diamond-like carbon (DLC) coating, which is available to satisfactory cut the reinforcing fibres as well as the soft matrix. This article compared the ultrasonic-assisted face milling of the carbon fibre reinforced plastic (CFRP) and glass fibre reinforced plastic (GFRP) by a unique shaped milling cutter. Delamination of those composite materials during the milling process was observed via 3D digitization devices. The results of the research could be applied to determine how a fibre material can affect the ultrasonic assistance during the milling process. Lower delamination during machining of GFRP was achieved; however, lower surface roughness was obtained during the machining of CFRP.