Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

doi:10.1007/s11465-022-0680-8

Front. Mech. Eng.

2022, Vol. 17

Issue (2) : 24 https://doi.org/10.1007/s11465-022-0680-8

REVIEW ARTICLE

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Teng GAO¹, Yanbin ZHANG¹, Changhe LI¹(

), Yiqi WANG², Yun CHEN³, Qinglong AN⁴, Song ZHANG⁵, Hao Nan LI⁶, Huajun CAO⁷, Hafiz Muhammad ALI⁸, Zongming ZHOU⁹, Shubham SHARMA¹⁰

¹. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China
². School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
³. Chengdu Tool Research Institute Co., Ltd., Chengdu 610500, China
⁴. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
⁵. School of Mechanical Engineering, Shandong University, Jinan 250061, China
⁶. School of Aerospace, University of Nottingham Ningbo China, Ningbo 315100, China
⁷. School of Mechanical Engineering, Chongqing University, Chongqing 400044, China
⁸. Mechanical Engineering Department, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia
⁹. Hanergy (Qingdao) Lubrication Technology Co., Ltd., Qingdao 266100, China
¹⁰. Department of Mechanical Engineering, IK Gujral Punjab Technical University, Punjab 144603, India

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Abstract

Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

Keywords milling grinding fiber-reinforced composites damage formation mechanism delamination material removal mechanism surface integrity minimum quantity lubrication

Corresponding Author(s): Changhe LI

About author:

Tongcan Cui and Yizhe Hou contributed equally to this work.

Just Accepted Date: 01 March 2022 Issue Date: 30 June 2022

Cite this article:

Teng GAO,Yanbin ZHANG,Changhe LI, et al. Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies[J]. Front. Mech. Eng., 2022, 17(2): 24.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0680-8
https://academic.hep.com.cn/fme/EN/Y2022/V17/I2/24

Fig.1 Logical relationship of integral structure. Reproduced with permission from Refs. [13,30,31] from Elsevier.

Fig.2 Mechanism of milling delamination. Part of this figure was drawn based on Refs. [48,49] to introduce their comments. Reproduced with permission from Refs. [47] from SAGE Publications.

Fig.3 Burr formation mechanism of fiber-reinforced composites in edge milling and slot milling. Reproduced with permission from Refs. [31,57?59] from Elsevier and Springer Nature.

Fig.4 Material removal mechanism of fiber-reinforced composite grinding. Reproduced with permission from Refs. [25,67?69] from Elsevier and Springer Nature.

Fig.5 Various experimental devices of single grain grinding. Reproduced with permission from Refs. [74,75,83] from Elsevier and Springer Nature.

Fig.6 Mechanical behavior of fiber reinforced composites grinding. Reproduced with permission from Refs. [71,74,77,86] from Elsevier.

Fig.7 Grinding damage mechanism and surface roughness trend. Part of the figure was drawn based on Ref. [98]. Reproduced with permission from Refs. [77,97] from Elsevier.

Reference	Vibration mode	Amplitude/μm	Frequency/kHz	Composites	Output parameters (compared with CM)
Wang et al. [13]	1D horizontal	2; 4; 5	28	UD-CFRP	?
Liu et al. [90]	1D longitudinal	10	20	MD-CFRP	?
Wang et al. [96]	1D longitudinal	?	20	UD-CFRP	?
Xu et al. [104]	Longitudinal–torsional	6; 3	22.5	AFRP	Cutting force: ↓ 15%?48%
Chen et al. [112]	Longitudinal–torsional	Longitudinal amplitude (LA)/torsional amplitude (TA) = 14/5;LA = 3; 8; 11	19.3	2D C/SiC	Specific grinding energy: ≈ ↓ max 50%;S_a: ≈ ↓ max 38%
Ding et al. [113]	1D longitudinal	3.85	21.5	2D C/SiC	F_n: ↓ 9%?21%;F_t: ↓ 9.7%?19.4%;S_a: ↓ 6.6%?12%;Fracture size: ↓ 25%
Ning et al. [114]	Horizontal–vertical	3	20	MD-CFRP	?
Xue et al. [115]	1D longitudinal	4; 6; 8; 10	20	3D C/SiC	Standard deviation of height of each point in the area S_q: ↓ 37.9%;fatigue damage rate: ↓ 31%?80%
Wang et al. [120]	Horizontal;horizontal–vertical	Horizontal 4;vertical 6	28; 20	CFRP	Cutting force: ≈ ↓ 21%?36%;surface roughness: ≈ ↓ 50%?62%
Amin et al. [122,123,129]	1D longitudinal	10	16; 20.5	MD-CFRP	?
Wang et al. [124]	1D longitudinal	4; 6; 7; 8	20		?
Ning et al. [125]	1D longitudinal	4; 5; 6; 7; 8	20	MD-CFRP	?
Li et al. [126]	1D longitudinal	6	20	MD-CFRP	?
Wang et al. [127]	1D longitudinal	?	20	MD-CFRP	?
Xue et al. [128]	1D longitudinal	10	20	3D C/SiC	Distance between the highest and lowest points of the contour R_t: ↓ 37.5%; R_a: ↓ 32.4%; R_z: ↓ 32.8%
Yuan et al. [130]	1D longitudinal	10; 15	?	MD-CFRP	?
Liu et al. [131]	1D longitudinal	2; 4; 6; 8; 10	21.19	C/SiC	F_x: ↓ 43.7%; F_y: ↓ 9.16%; F_z: ↓ 68.09%; R_a: ≈ ↓ 12%?16.7%
Chen et al. [132]	Longitudinal?torsional	LA/TA = 14/5;LA = 2; 4; 6; 7	19.32	2D C/SiC	Temperature: ↓ 30.4%; specific milling energy: ≈ ↓ 33.3%; S_a: ≈↓ 28.6%
Xie et al. [133]	1D longitudinal	2; 4; 6; 8; 10	23.98	2.5D C/SiC	F_x: ↓ 27%; F_y: ↓ 49.5%; F_z: ↓ 28.6%; S_a: ↓ 53%
Geng et al. [134]	Double bending	9.6	20.73	CFRP	F_x: ↓ 8%?27%; F_y: ↓ 12%?43%; F_z: ↓ 2%?40%; surface roughness: ↓ 54%
Shu et al. [135]	1D longitudinal	10	30	C/C	Fiber pull-out length: ↓ 10%?50%
Zhang et al. [136]	1D longitudinal	15	21.5	C/SiC	?
Islam et al. [137]	1D longitudinal	?	17	C/SiC	?
Liang et al. [138]	1D longitudinal	5	20?30	MD-CFRP	?
Li et al. [139]	1D longitudinal	?	26.5	2.5D SiO₂/SiO₂	Grinding forces: ↓ 30%?35%;S_q: ↓ 12.5%; maximum height of 2D profile S_z: ↓ 12.3%
Wang et al. [140]	1D longitudinal	4	21.2	C/SiC	Grinding forces: ≈ ↓ max 60%
Wang et al. [141]	Vertical;vertical?horizontal	4; 6	?	CFRP	Vertical vibration:F_x: ↓ 11%?20%;F_z: ↓ 12%?40%;S_a: ↓ 12%?21%.Vertical?horizontal vibration:F_x: ↓ 21%?57%;F_z: ↓ 30%?52%;S_a: ↓ 50%?60%
Azarhoushang and Tawakoli [142]	1D tangential	8	20	C/SiC	Grinding forces: ≈ ↓ max 20%;surface roughness R_a and R_z : ≈ ↓ max 30%;G-ratio: ≈ ↑ 30%?40%;radial wear: ≈ ↓ max 28%?45%
Chen et al. [143]	1D longitudinal	14	29.7	CFRP	?
Liang et al. [144]	1D longitudinal	4	26	UD-CFRP	F_t: ↓ max 19% at 135°;F_n: ↓ max 7.2% at 135°;maximum fiber chip length: ≈ ↓ 66%?78%;S_a: ↓ max 17.7%

Tab.1 Ultrasonic vibration parameters and output parameters

Fig.8 Damage suppression mechanism of ultrasonic vibration assisted machining. UVAS: ultrasonic vibration-assisted scratching. Reproduced with permission from Refs. [112?115] from Elsevier and Springer Nature.

Tab.2 Cryogenic cooling conditions and output parameters

Fig.9 Mechanisms and advantages of cryogenic cooling in the machining of fiber-reinforced composites. Reproduced with permission from Refs. [31,158] from Elsevier.

Tab.3 MQL conditions and output parameters

Fig.10 Lubrication mechanism, force reduction mechanism, and beneficial effects of MQL and NMQL. Reproduced with permission from Refs. [100,187,208] from Elsevier.

Fig.11 Typical optimization design of milling and grinding tools. Reproduced with permission from Refs. [138,213?217] from Springer Nature, SAGE Publications, and Elsevier.

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