Comparative Analysis of Tooling Methods for Delamination Formations in the Edge Trimming Process of High-Modulus CFRP for Space Applications
摘要
This paper presents a comparative analysis of three tooling methods utilized in the edge trimming process of high-modulus carbon fiber reinforced polymer (CFRP) composites consisting of high-modulus HR40 carbon fibers intended for space structures. The study focuses on assessing delamination formations, a critical concern in CFRP machining. The three tooling methods investigated are 1) conventional mechanical clamping at room temperature, 2) conventional mechanical clamping at freezing temperature, and 3) ice clamping using frozen water to adhere to the workpiece. Edge trimming experiments were conducted using a CVD-diamond coated hybrid router with two conditions, fresh tool and worn tool, at four different fiber orientations (0°, 45°, 90°, and 180°). All the experiments had the constant process condition at a feed of 1 m/min, a spindle speed of 6000 rpm, and a cut width of 1.27 mm. The cutting forces in the ice clamping method are higher than those of mechanical clamping at room and freezing temperature conditions by 24% and 9%, respectively. Delamination formations are dependent on the fiber orientation; however, they are highly impacted by the clamping method. Ice clamping resulted in the lowest delamination depth and uncut fiber length regardless of the tool condition to show its effectiveness in mitigating ply deformation during edge trimming.