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Publisher DOI: 10.1016/j.procir.2014.03.103
Title: Constant depth scoring of fibre reinforced plastic structures to prevent delamination
Language: English
Authors: Geis, Tobias 
Klingelhöller, Christian 
Hintze, Wolfgang 
Keywords: combined process;delamination;Fibre reinforced plastic;grinding;milling;scoring
Issue Date: 2014
Publisher: Elsevier
Source: Procedia CIRP (14): 205-210 (2014)
Journal or Series Name: Procedia CIRP 
Abstract (english): Scoring of the outer layers of a workpiece with small engagement (ae) using circular saws is a well known method to avoid unwanted delamination of these layers, such as coatings of wooden particle boards. In edge milling fibre reinforced plastics (FRP), delamination also occurs in the top or bottom layer of the component and requires time intensive rework or scrapping of material. A combined process of scoring and milling is presented in this paper as a means to avoid delamination during machining of FRP structures such as aircraft carbon FRP parts. For the scoring process a diamond electroplated circular wheel is used. To guarantee a constant width of the scored slot, a constant depth of engagement is needed due to the shape of the grinding wheel. Therefore the profile of the scoring path on the workpiece surface is measured with respect to the machine coordinate system to correct a variation in the workpiece thickness and to compensate for uneven clamping. Next, the workpiece is scored with constant depth of engagement (ae,s < 0.5 mm) and a high feed velocity of up to 16 m/min. Subsequently, the scored component is machined with a conventional polycrystalline diamond (PCD) milling tool. From experiments it is proven that a delamination-free edge is achievable even with a worn tool (cutting edge radius rn > 50 μm) at an increased feed velocity (vf,m = 4.5 m/min). Without scoring, flawed workpiece edges have been obtained with cutting edge radii beyond rn > 23 μm (progressive uniform wear stage) and a feed velocity of vf,m = 1.5 m/min. Hence, high performance cutting (HPC) edge milling of composites may be realized by an initial scoring step to fulfil quality requirements of the machined edges and simultaneously increase the tool life of the milling tool. © 2014 Published by Elsevier B.V.
Conference: 6th CIRP International Conference on High Performance Cutting, HPC2014 
DOI: 10.15480/882.2382
ISSN: 2212-8271
Institute: Produktionsmanagement und -technik M-18 
Type: (wissenschaftlicher) Artikel
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