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Micro-machining of UHMWPE composites reinforced with carbide fillers

100%

Gürgen S. , Sofuoğlu M. A.

Archives of Civil and Mechanical Engineering

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2021

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tom Vol. 21, no. 4

189--202

EN

Polymer matrix composites (PMCs) have become one of the most widely used engineering materials due to both the developments in polymers and advanced fillers. It is expected that polymer composites will take their final shape during the production phase, which means that they are not required to undergo new processes. However, in some applications, machining operations, such as turning, milling, grooving and hole drilling, cannot be avoided and thus, finishing operations must be applied to these materials. Since these materials have complex microstructures, finishing operations may cause situations that adversely affect engineering properties, such as matrix cracking, delamination, debonding, etc. In this study, micro-milling operations were performed for recently developed ceramic reinforced polymer composites. Three different spindle speeds were used while feed rate and cutting depth were kept constant in the operations. The composites were produced from powdered UHMWPE and silicon carbide particles. Several parameters were varied in the production of the composites, such as molding pressure, filler loading and filler size. The investigated outputs were cutting temperature and surface roughness, whereas machined surfaces and chip morphologies were also investigated via microscopy analyses. In the final stage, regression analyses were performed to investigate the relationships between the process parameters. According to the results, ceramic reinforced polymer composites exhibit different machinability properties than fiber-reinforced ones due to hard fillers and low melting point of UHMWPE.

2

Optimization of micromachining operation for particle reinforced UHMWPE composites

100%

Sofuoğlu M. A. , Gürgen S.

Archives of Civil and Mechanical Engineering

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2022

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tom Vol. 22, no. 3

art. no. e138

EN

Unlike metals, polymers are highly affected by the heat generation during the machining of the workpiece, because the thermal conductivity of polymers are considerably lower than metals, and therefore heat is much more effective in the cutting zone. If the appropriate cutting parameters are not selected, the polymers become excessively deformed and the final part has high surface roughness, dimensionally large burr formation, or dimensional deviations. Machining of polymers ultra-high molecular weight polyethylene (UHMWPE) is quite common in industrial applications. In this study, the effect of SiC fillers on the machinability of UHMWPE polymer composite was investigated. First, different samples were produced using different filler sizes (1 μm, 50 μm, and 100 μm) and different filler amounts (1%, 3%, 5%). Micro-milling tests were carried out at a constant feed rate (70 mm/min), constant cutting depth (0.1 mm) and spindle speeds (1200, 2800, and 4400 rpm). Tool overhang lengths were selected as 10, 15, and 20 mm. During the experiments, the surface/burr shapes, cutting temperatures and cutting forces were observed. In general, it is observed that SiC filler reduces cutting forces and cutting temperatures. In the further stage of the study, Taguchi analysis was performed in the light of different SiC filler sizes, filler amounts, rotational speeds, and tool overhang lengths.

3

Anti‑impact and vibration‑damping design of cork‑based sandwich structures for low‑speed aerial vehicles

80%

Sheikhi M. R. , Gürgen S. , Altuntas O. , Sofuoğlu M. A.

Archives of Civil and Mechanical Engineering

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2023

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tom Vol. 23, no. 2

art. no. e71, 2023

EN

Nowadays, lightweight and eco-friendly composites with improved mechanical properties are highly interesting. Sandwich-structured composites are a type of high-performance structural composite that is lightweight with a high strength-to-weight ratio and excellent specifc energy absorption capabilities. In this study, cork-based sandwich structures resistant to impact and vibrations were designed and produced for the possibility of being used in the protective structures of low-speed aerial vehicles. To identify and match the best combination of different face sheets with a cork core, first, aramid fabric-reinforced polymer (AFRP), carbon fiber-reinforced polymer (CFRP), and glass fiber-reinforced polymer (GFRP) face-sheet composites were produced using the compression molding method (prepreg layup). Then, sandwich structures consisting of AFRP, CFRP, GFRP, and aluminum face sheets with a fixed core layer of cork were designed and assembled. Since the design goal of these structures is to use them in low-speed aerial vehicles, impact deceleration and vibration tests were applied to face sheets and sandwich structures individually, which are the most important factors involved in these structures during fight, particularly in rotary-wing drone applications. A low-energy drop-tower system was used for the calculation of deceleration results. Besides, the vibration properties of the structures were investigated using the modal analysis method and based on the natural frequency responses of the tested face sheets and sandwich structures, damping ratios and structural stiffness were measured. According to the results, compared to other face sheets, CFRP showed better resistance along with the cork core, when the structure was exposed to impact and vibration threats. This study provides useful information on cork core sandwich structures for academic and industrial researchers in choosing the right face sheet.