Machining Technology for Composite Materials

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Part I: Traditional methods for machining composite materials

Chapter 1: Turning processes for metal matrix composites

Abstract:

1.1 Introduction

1.2 Turning of metal matrix composites (MMCs)

1.3 Cutting tools for turning Al/SiC based MMCs

1.4 Cutting with rotary tools

1.5 Conclusions

Chapter 2: Drilling processes for composites

Abstract:

2.1 Introduction

2.2 Delamination analysis

2.3 Delamination analysis of special drills

2.4 Delamination analysis of compound drills

2.5 Delamination measurement and assessment

2.6 Influence of drilling parameters on drilling-induced delamination

2.7 Conclusions

Chapter 3: Grinding processes for polymer matrix composites

Abstract:

3.1 Introduction

3.2 Applications of grinding processes for composites

3.3 Problems associated with the grinding of composites

3.4 Various factors affecting the grinding of composites

3.5 Future trends

3.6 Sources of further information

Chapter 4: Analysing cutting forces in machining processes for polymer-based composites

Abstract:

4.1 Introduction

4.2 Orthogonal cutting of unidirectional composites

4.3 Drilling

4.4 Milling

4.5 Conclusions and recommended future research

4.6 Sources of further information

4.8 Appendix: List of symbols used

Chapter 5: Tool wear in machining processes for composites

Abstract:

5.1 Introduction

5.2 Tool materials

5.3 Tool wear

5.4 Tool wear in machining metal matrix composites

5.5 Tool wear in machining polymeric matrix composites

5.6 Tool life

5.7 Conclusions

Chapter 6: Analyzing surface quality in machined composites

Abstract:

6.1 Introduction

6.2 General concepts of an engineering surface

6.3 Surface quality in machining

6.4 Influence of cutting parameters on surface quality

6.5 Conclusions

Part II: Non-traditional methods for machining composite materials

Chapter 7: Ultrasonic vibration-assisted (UV-A) machining of composites

Abstract:

7.1 Introduction

7.2 Ultrasonic vibration-assisted (UV-A) turning

7.3 UV-A drilling

7.4 UV-A grinding

7.5 Ultrasonic machining (USM)

7.6 Rotary ultrasonic machining (RUM)

7.7 UV-A laser-beam machining (LBM)

7.8 UV-A electrical discharge machining (EDM)

7.9 Conclusions

Chapter 8: Electrical discharge machining of composites

Abstract:

8.1 Introduction

8.2 Principles of electrical discharge machining (EDM)

8.3 Electrically conductive ceramic materials and composites

8.4 EDM of ceramic composites: understanding the process–material interaction

8.5 New generator technology for EDM

8.6 EDM strategies and applications

8.7 Conclusions

8.8 Acknowledgments

Chapter 9: Electrochemical discharge machining of particulate reinforced metal matrix composites

Abstract:

9.1 Introduction

9.2 The principles of electrochemical discharge machining (ECDM)

9.3 ECDM equipment

9.4 Parameters affecting material removal rate (MRR)

9.5 Parameters affecting surface roughness

9.6 Conclusions

9.7 Acknowledgement

Chapter 10: Fundamentals of laser machining of composites

Abstract:

10.1 Introduction

10.2 Fundamentals of laser machining

10.3 Laser machining of metal matrix composites (MMCs)

10.4 Laser machining of non-metallic composites

10.5 Conclusions

Chapter 11: Laser machining of fibre-reinforced polymeric composite materials

Abstract:

11.1 Introduction

11.2 Effect of laser and process gas

11.3 Effect of materials

11.4 Quality criteria

11.5 Conclusions

Chapter 12: Laser-based repair for carbon fiber reinforced composites

Abstract:

12.1 Introduction

12.2 Carbon fiber reinforced polymer (CFRP) repair principles

12.3 UV laser–CFRP interaction

12.4 The laser-based repair process for CFRP

12.5 Conclusions

Part III: Special topics in machining composite materials

Chapter 13: High speed machining processes for fiber-reinforced composites

Abstract:

13.1 Introduction

13.2 Overview of high speed drilling (HSD) of fiber-reinforced polymers (FRPs)

13.3 Thermal aspects and cutting forces in HSD of FRPs

13.4 Tribological aspects in HSD of FRPs

13.5 Hole quality

13.6 Overview of high speed milling of FRPs

13.7 Dynamic characteristics in high speed milling of FRPs

13.8 Cutting forces and thermal aspect in high speed milling of FRPs

13.9 Surface quality and geometrical errors

Chapter 14: Cryogenic machining of composites

Abstract:

14.1 Introduction

14.2 Key aspects of cryogenic science

14.3 State-of-the-art cryogenic machining

14.4 Cryogenic machinability of composite materials

14.5 Conclusions

14.6 Acknowledgments

Chapter 15: Analyzing the machinability of metal matrix composites

Chapter 16: Machining processes for wood-based composite materials

Chapter 17: Machining metal matrix composites using diamond tools

Abstract:

17.1 Introduction

17.2 Tool life, productivity and tool failure/wear mechanisms

17.3 Machined surface and sub-surface integrity

17.4 Chip formation and mechanics of machining

17.5 Conclusions and future trends

17.6 Acknowledgments

Index

Machining processes play an important role in the manufacture of a wide variety of components. While the processes required for metal components are well-established, they cannot always be applied to composite materials, which instead require new and innovative techniques. Machining technology for composite materials provides an extensive overview and analysis of both traditional and non-traditional methods of machining for different composite materials.

The traditional methods of turning, drilling and grinding are discussed in part one, which also contains chapters analysing cutting forces, tool wear and surface quality. Part two covers non-traditional methods for machining composite materials, including electrical discharge and laser machining, among others. Finally, part three contains chapters that deal with special topics in machining processes for composite materials, such as cryogenic machining and processes for wood-based composites.

With its renowned editor and distinguished team of international contributors, Machining technology for composite materials is an essential reference particularly for process designers and tool and production engineers in the field of composite manufacturing, but also for all those involved in the fabrication and assembly of composite structures, including the aerospace, marine, civil and leisure industry sectors.

• Provides an extensive overview of machining methods for composite materials
• Chapters analyse cutting forces, tool wear and surface quality
• Cryogenic machining and processes for wood based composites are discussed

Process designers and tool and production engineers in the field of composite manufacturing, but also for all those involved in the fabrication and assembly of composite structures, including the aerospace, marine, civil and leisure industry sectors.