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Title: Milling/routing of carbon fibre reinforced plastic (CFRP) composites
Author: El-Hofy, Mohamed Hassan
ISNI:       0000 0004 5350 4886
Awarding Body: University of Birmingham
Current Institution: University of Birmingham
Date of Award: 2014
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The research relates to a study on the routing/slotting of CFRP composites of the type used in aerospace applications. Following a literature review, 3 phases of experimental work were undertaken to evaluate the effects of key process variables on the machinability of CFRP. The influence of varying operating parameters, tool material and cutting environment were initially investigated in Phase 1 work. The results showed that use of PCD was critical and highlighted the importance of chilled air in maintaining adequate tool life and acceptable workpiece integrity. Delivery of chilled air through a single-nozzle arrangement generally led to an increase in forces and delamination with the twin-nozzle configuration showing superior workpiece surface roughness. Phase 2 work detailed the effect of workpiece lay-up configuration on cutting forces, temperature and surface integrity following slotting and routing. Plies in the 45 direction generally exhibited the highest level of surface damage following machining. Experiments in Phase 3 showed that relatively small helix angles (± 3) had a negligible effect on tool life, forces and temperature. In addition, cutters with a single relief angle were found to have lower stability in operation compared to tools with a secondary clearance angle, with detrimental effects on surface roughness.
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available
Keywords: TJ Mechanical engineering and machinery