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Composites: Alen P Rajan S4 Mechanical G.P.T.C Adoor 2201020670 Sri: Dileep M.V GPTC Adoor

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4 views

Composites: Alen P Rajan S4 Mechanical G.P.T.C Adoor 2201020670 Sri: Dileep M.V GPTC Adoor

Uploaded by

xtuartx
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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COMPOSITES

GUIDED BY: PRESENTED BY:


SRI : DILEEP M.V ALEN P RAJAN
LECTURE IN MECHANICAL ENGINEERING S4 MECHANICAL
G.P.T.C ADOOR
GPTC ADOOR
2201020670
CONTENTS

 INTRODUCTION
 DEFINITION OF COMPOSITES
 FIBER-REINFORCED COMPOSITES
 CHARACTERISTICS
 APPLICATIONS
 ADVANCED TOOL TECHNOLOGIES
 CONCLUSION
INTRODUCTION
 1. Fiber-reinforced composites have high specific strength and stiffness,
making them ideal for aerospace equipment.
 4. Fiber composites are widely used in scientific, technological, and military
fields.
 They can be used to manufacture large and complex components with
reduced connections.
 Ceramic matrix composites (CMCs) are used in high-temperature applications,
replacing conventional materials.
WHAT IS COMPOSITES ?
 Composites refer to materials made from a combination of two or more
distinct materials, often with different properties, that are combined to form
a new material with unique properties. The individual components remain
distinct and do not merge completely, creating a strong bond between them
FIBER-REINFORCED COMPOSITES

 Fiber-reinforced composites (FRCs) are materials composed of:


 1. Fibers (e.g., carbon, glass, Kevlar, natural fibers) that provide strength,
stiffness, and toughness.
 2. Matrix(e.g., polymer, metal, ceramic) that binds the fibers together,
transferring loads between them.
 The fibers and matrix combine to form a strong, lightweight, and durable
material with unique properties. FRCs are also known as fiber-reinforced
polymers (FRP) or composite materials.
CHARACTERISTICS
 High strength-to-weight ratio
 Improved stiffness and toughness
 Enhanced fatigue resistance
 Corrosion and wear resistance
 Tailored properties for specific applications
APPLICATIONS
FINISHING OPERATIONS
 MILLING
 GRINDING
 MILLING : Milling is a machining process that uses a rotating tool to remove
material from a workpiece by advancing (moving) the tool along a
predetermined path. The tool, typically a milling cutter or drill bit, is rotated
at high speed and moved in various directions to achieve the desired shape or
surface finish.
MACHINING DAMAGES
 DELAMINATION
 BURR
 TEAR

 DELAMINATION
 Delamination occurs in the milling process due to high interlaminar stress and
low interlaminar strength of fiber laminates.
 Delamination directly affects the strength and fatigue resistance of
composites
MACHINING DAMAGES

BURR
 Burr formation occurs when delamination happens, and fibers are not
completely cut off by the milling too

 TEAR
 It Is a type of defect or damage that occurs on the workpiece surface during
the machining process
 Tearing can lead to a poor surface finish, reduced part accuracy, and
decreased structural integrity
 Defects when the tensile force is greater than the tensile strength of the
fiber.
GRINDING
 Grinding operation in fiber reinforced composites (FRCs) is a machining
process that involves the removal of material from the composite surface
using an abrasive tool, such as a grinding wheel or a diamond file. The goal of
grinding is to achieve a specific surface finish, remove defects, or prepare the
surface for further processing.
ADVANCED CUTTING TOOLS AND
TECHNOLOGIES
 ULTRA SONIC VIBRATION ASSISTED MACHINING

 CYROGENIC COOLING

 MINIMUM QUANTITY LUBRICATION


ULTRASONIC VIBRATION ASSISTED
MACHINING

 UVAM combines ultrasonic vibration with traditional machining to improve the


removal mechanism and machining performance.
 High-frequency ultrasonic vibration is added to the tool or workpiece to change
the removal mechanism.
 UVAM is effective in reducing cutting force, improving surface quality, and
increasing tool life
CYROGENIC COOLING

 Cryogenic cooling is essential in machining carbon fiber reinforced polymers


(CFRP) to control the cutting zone temperature and improve machining quality.
 The fracture properties of fibers are improved at low temperatures.
 Cryogenic cooling reduces fiber/matrix debonding and improves the fiber matrix
interface strength
MINIMUM QUANTITY LUBRICATION

 Minimum quantity lubrication (MQL) is a new cooling and lubrication technology that uses a mixture of high -
pressure gas and minimal lubricating oil to form an oil mist.
 MQL has been shown to have advantages in machining fiber composites, including reducing friction and tool
wear, and improving surface quality.
 MQL can reduce cutting forces and surface roughness, and improve grinding efficiency compared to dry
grinding
CONCLUSION AND FUTURE CHALLENGES
 Various aspects of machining fiber-reinforced composites, including:
 1. Delamination: Interlayer and surface delamination can occur due to the
lack of sufficient matrix supporting force on the surface fiber, leading to
cracks and delamination.
 2. Failure modes: Fiber fracture, matrix fracture or crack, and interface
debonding are the main failure modes in grinding fiber composites.
 3. Ultrasonic vibration-assisted machining (UVAM): UVAM can reduce cutting
forces, improve surface quality, and increase material removal rates.
 Highlights the challenges and complexities involved in machining fiber-
reinforced composites and the need for further research to understand the
underlying mechanisms and develop effective machining techniques.
REFERENCE
 Wang H, Hu Y B, Cong W L, Hu Z L. A mechanistic model on feeding-
directional cutting force in surface grinding of CFRP
composites using rotary ultrasonic machining with horizontal
ultrasonic vibration. International Journal of Mechanical
Sciences, 2019, 155: 450–460
 Handa D, Sooraj V S. An eccentric sleeve grinding strategy for fibre-
reinforced composites. Composites Part B: Engineering, 2019, 176: 107332
 Fiber-reinforcedcomposites in milling andgrinding:machining bottlenecks and
advanced strategiesTeng GAOa, YanbinZHANGa, Changhe LI ( )a, Yiqi
WANGb,Yun CHENc,Qinglong ANd,Song ZHANGe,Hao Nan LIf,Huajun
CAOg,Hafiz Muhammad ALIh,Zongming ZHOUi,Shubham SHARMAj
THANK YOU .....

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