Machining technology for composite materials

- 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
- an essential reference for process designers and production engineers in composite manufacturing, and those involved in composite structures in various industries

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.

Hong Hocheng is a University Chair Professor in the Department of Power Mechanical Engineering at the National Tsing Hua University, Taiwan, ROC.

PART 1 TRADITIONAL METHODS FOR MACHINING COMPOSITE MATERIALS

Turning processes for metal matrix composites
H A Kishawy, University of Ontario Institute of Technology (OUIT), Canada
 - Introduction
 - Turning of metal matrix composites (MMCs)
 - Cutting tools for turning Al / SiC-based MMCs
 - Cutting with rotary tools
 - Conclusions
 - References

Drilling processes for composites
C C Tsao, Tahua Institute of Technology, Taiwan
 - Introduction
 - Delamination analysis
 - Delamination analysis of special drills
 - Delamination analysis of compound drills
 - Delamination measurement and assessment
 - Influence of drilling parameters on drilling-induced delamination
 - Conclusions
 - References

Grinding processes for polymer matrix composites
S D El Wakil, University of Massachusetts Dartmouth, USA
 - Introduction
 - Applications of grinding processes for composites
 - Problems associated with the grinding of composites
 - Various factors affecting the grinding of composites
 - Future trends
 - Sources of further information
 - Bibiliography

Analysing cutting forces in machining processes for polymer-based composites
G Caprino and A Langella, University of Naples Federico II, Italy
 - Introduction
 - Orthogonal cutting of unidirectional composites
 - Drilling
 - Milling
 - Conclusions and recommended future research
 - Sources of further information
 - References
 - Appendix: list of symbols

Tool wear in machining processes for composites
J Sheikh-Ahmad, The Petroleum Institute, UAE and J P Davim, University of Aveiro, Portugal
 - Introduction
 - Tool materials
 - Tool wear
 - Tool wear in machining metal matrix composites
 - Tool wear in machining polymeric matrix composites
 - Tool life
 - Conclusions
 - References

Analysing surface quality in machined composites
K Palanikumar, Sri Sairam Institute of Technology, India
 - Introduction
 - General concepts of an engineering surface
 - Surface quality in machining
 - Influence of cutting parameter on surface quality
 - Conclusions
 - References

PART 2 NON-TRADITIONAL METHODS FOR MACHINING COMPOSITE MATERIALS

Ultrasonic vibration-assisted (UV-A) machining of composites
Q Feng and C Z Ren, Tianjin University, China and Z J Pei, Kansas State University, USA
 - Introduction
 - Ultrasonic vibration-assisted (UV-A) turning
 - UV-A drilling
 - UV-A grinding
 - Ultrasonic machining (USM)
 - Rotary ultrasonic machining (RUM)
 - UV-A laser beam machining (LBM)
 - UV-A electrical discharge machining (EDM)
 - Conclusions
 - References

Electrical discharge machining of composites
B Lauwers, J Vleugels, O Malek, K Brans and K Liu, Katholieke Universiteit Leuven, Belgium
 - Introduction
 - Principles of electrical discharge machining (EDM)
 - Electrically conductive ceramic materials and composites
 - EDM of ceramic composites: understanding the ‘process – material’ interaction
 - New generator technology for EDM
 - EDM strategies and applications
 - Conclusions
 - Acknowledgements
 - References

Electrochemical discharge machining of particulate-reinforced metal matrix composites
J W Liu, South China University of Technology, PR China and T M Yue, The Hong Kong Polytechnic University, Hong Kong
 - Introduction
 - Principles of electrochemical discharge machining (ECDM)
 - ECDM equipment
 - Parameters affecting material removal rate (MRR)
 - Parameters affecting surface roughness
 - Conclusions
 - Acknowledgement
 - References

Fundamentals of laser machining of composites
G Chryssolouris and K Salonitis, University of Patras, Greece
 - Introduction
 - Fundamentals of laser machining
 - Laser machining of metal matrix composites (MMCs)
 - Laser machining of non-metallic composites
 - Conclusions
 - References

Laser machining of fiber-reinforced polymeric composite materials
R Negarestani and L Li, University of Manchester, UK
 - Introduction
 - Effect of laser and process gas
 - Effect of materials
 - Quality criteria
 - Conclusions
 - References

Laser-based repair for carbon fiber reinforced composites
F Fischer, Laser Zentrum Hannover e.V., Germany and L Romoli, University of Pisa, Italy
 - Introduction
 - Carbon fiber reinforced polymer (CFRP) repair principles
 - UV laser-CFRP interaction
 - The laser-based repair process for CFRP
 - Conclusions
 - References

PART 3 SPECIAL TOPICS IN MACHINING COMPOSITE MATERIALS

High speed machining processes for fibre-reinforced composites
H Attia, National Research Council of Canada and McGill University, A Sadek, McGill University and M Meshreki, National Research Council of Canada, Canada
 - Introduction
 - Overview of high speed drilling (HSD) of fibre-reinforced polymers (FRPs)
 - Thermal aspects and cutting forces in HSD in FRPs
 - Tribological aspects of HSD of FRPs
 - Produced hole quality
 - Overview of high speed milling of FRPs
 - Dynamic characteristics in high speed milling of FRPs
 - Cutting forces and thermal aspects in high speed milling of FRPs
 - Surface quality and geometrical errors
 - References

Cryrogenic machining of composites
Y Yildiz, Dumlupinar University, Turkey and M M Sundaram, University of Cincinnati, USA
 - Introduction
 - Key aspects of cryogenic science
 - State of the art cryogenic machining
 - Cryogenic machinability of composite materials
 - Conclusions
 - Acknowledgements
 - References

Analysing the machinability of metal matrix composites
M Balazinski, École Polytechnique de Montréal, V Songmene, Université du Québec and H A Kishawy, University of Ontario Institute of Technology (UOIT), Canada
 - Effect of the nature of the particle: soft and hard particles
 - Chip formation
 - Effect of particle shape
 - Effect of particle size
 - Effect of particle volume fraction on tool wear and cutting forces
 - Conclusions
 - References

Machining processes for wood-based composite materials
G Kowaluk, Wood Technology Institute, Poland
 - Introduction
 - Wood-based composite materials
 - Major machining techniques
 - Selected machining problems
 - Future trends
 - Conclusions
 - References

Machining metal matrix composites using diamond tools
S S Joshi, Indian Institute of Technology Bombay, India
 - Introduction
 - Tool life, productivity and tool failure / wear mechanism
 - Machined surface and sub-surface integrity
 - Chip formation and mechanics of machining
 - Conclusions and future trends
 - Acknowledgements
 - References