Model based prediction of force and roughness extrema inherent in machining of fibre reinforced plastics using data merging

Planning of machining operations for fibre reinforced plastics components today entails expensive trials in order to meet quality, productivity and cost requirements. The use of existing data for modeling and simulation has so far been severely limited due to the lack of universal process models that capture fundamental mechanisms in a process-independent approach and thus allow data to be merged across different cutting processes. Recently, a universal model describing the engagement conditions in oblique cutting of unidirectional FRPs has been developed. The model closes the gap described and builds the basis for cross-technology data merging from different cutting operations, which has been common practice for homogenous materials for a long time. In case of mostly thin FRP components and often poor clamping conditions the generated forces in cutting operations are crucial as they may lead to dynamic process instabilities and to unfavorable part deflections impeding part precision. Furthermore, the quality of the machined surface depends on the engagement conditions, which usually change significantly during machining. Force and quality data from different sources and across various cutting processes and FRP materials were merged using the universal engagement model to reveal generally applicable relationships. These will enable faster, more reliable and more cost-efficient planning of cutting operations for FRP components in the future.

Subjects

Data-based modeling

Production at the leading edge of technology

Fibre reinforced plastics

Modelling

DDC Class

380: Handel, Kommunikation, Verkehr

Options

Model based prediction of force and roughness extrema inherent in machining of fibre reinforced plastics using data merging