On the mechanics and material removal mechanisms of vibration-assisted cutting of unidirectional fibre-reinforced polymer composites |
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| Affiliation: | 1. Bilkent University, Department of Industrial Engineering, Bilkent, Ankara, Turkey;2. Turkish Aerospace Industries (TAI), Kazan, Ankara, Turkey;3. Atılım University, Department of Manufacturing Engineering, İncek, Ankara, Turkey;1. Jiangsu Key Laboratory and Micro-Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China;2. Beijing Xinghang Mechanical and Electrical Equipment Co., Ltd., Beijing 100000, China;1. Lebanese University, Faculty of Engineering, Mechanical Engineering Department, P.O. Box : 27622319, Roumieh, Lebanon;2. Université de Toulouse, INSA, UPS, Mines Albi, ISAE, ICA (Institut Clément Ader), Bât 3R1, 118 Route de Narbonne, F-31062 Toulouse cedex 9, France;1. State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;2. Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipments and Control, Beijing, 100084, China;3. Division of Advanced Manufacturing, Graduate School at Shenzhen, Tsinghua University, Shenzhen 518055, China;4. Beijing Xinghang Mechanical-Electrical Equipment Co., Ltd, Beijing, 100074, China |
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| Abstract: | This paper aims to reveal the material removal mechanisms and the mechanics behind the vibration-assisted cutting (VAC) of unidirectional fibre reinforced polymer (FRP) composites. Through a comprehensive analysis by integrating the core factors of the VAC, including fibre orientation and deformation, fibre–matrix interface, tool–fibre contact and tool–workpiece contact, a reliable mechanics model was successfully developed for predicting the cutting forces of the process. Relevant experiments conducted showed that the model has captured the mechanics and the major deformation mechanisms in cutting FRP composites, and that the application of ultrasonic vibration in either the cutting or normal direction can significantly decrease cutting forces, minimise fibre deformation, facilitate favourable fibre fracture at the cutting interface, and largely improve the quality of a machined surface. When the vibrations are applied to both the cutting and normal directions, the elliptic vibration trajectory of the tool tip can bring about an optimal cutting process. There exists a critical depth of cut, beyond which the fibre–matrix debonding depth is no longer influenced by the vibration applied on the tool tip. |
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| Keywords: | Fibre-reinforced polymer composites Vibration-assisted cutting Cutting mechanics Material removal mechanism Fibre–matrix debonding Fibre fracture |
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