Special Issue "Non-conventional Machining and Machinability of Composites"

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials".

Deadline for manuscript submissions: 28 February 2022.

Special Issue Editors

Dr. Sikiru Oluwarotimi Ismail
E-Mail Website
Guest Editor
Department of Engineering, School of Physics, Engineering and Computer Science, University of Hertfordshire, Hatfield, Hertfordshire AL10 9AB, UK
Interests: advanced machining processes (abrasive waterjet, electric discharge, etc.) and finishing technologies; materials and manufacturing (mechanical) engineering; process design and development/product innovation & technology transfer; innovative manufacturing/machining processes / monitoring and optimisation; advanced and digital manufacturing/robots in manufacturing, among others; using experimental and numerical simulation/finite element/analytical modelling techniques
Prof. Dr. Redouane Zitoune
E-Mail Website
Guest Editor
Université de Toulouse, INSA, UPS, Mines d’Albi, ISAE, ICA (Institut Clément Ader), IUT-A GMP Toulouse, 133 c Avenue de Rangueil, 31077 Toulouse, France
Interests: composite materials; machining; manufacturing engineering; materials science; multifunctional materials; instrumentation
Special Issues and Collections in MDPI journals
Prof. Dr. Joao Paulo Davim
E-Mail Website
Guest Editor
Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal
Interests: mechanical and industrial engineering; materials; machining; tribology; sustainable manufacturing; higher education for sustainability; engineering education
Special Issues and Collections in MDPI journals

Special Issue Information

Application of various composites is rapidly increasing among several manufacturing and composite-based industries. These include the automotive and aerospace sectors, among others. The wide use of composites can be attributed to their outstanding inherent properties, such as sustainability, renewability, recyclability, availability, high strengths and stiffness, environmentally friendliness, low cost, non-toxicity, relative ease of fabrication, thermal, chemical, electrical, corrosion resistance and acoustic, amongst others. In subtractive manufacturing technology, the machining process is very indispensable, as raw materials (workpieces) and engineering structures are required to be shaped to desirable geometries before their various structural applications. Importantly, this process attracts some associated machining-induced damage (MID) responses.

Moreover, there is some associated MID on composites that are either irrelevant or not well pronounced in other engineering materials, such as metals and alloys. Such MID include delamination, surface roughness, de-bonding, crack, matrix melting, matrix melting, fibre pull-out and uncut, to mention but a few. Therefore, non-conventional machining (NCM) was introduced to reduce or eliminate the aforementioned MID responses. NCM techniques include the following types:

  • Electron beam machining (EBM)
  • Abrasive/waterjet machining (A/WJM)
  • Ultrasonically-assisted machining (UAM)
  • Laser beam machining (LBM)
  • Electrical/Electron discharge machining (EDM)
  • Electrochemical machining (ECM) and
  • Other non-traditional/conventional machining processes (NCM)

Importantly, it is expected that NCM will become a key feature of future machining of various types of composites, including polymer matrix composites (PMC), metal matrix composites (MMC), and ceramic matrix composites (CMC) (based on matrix) as well as fibre-reinforced, particulate, and structural composites (based on reinforcement), amongst others. The aim of this Special Issue is to follow the state-of-the-art of evolution of NCM, publish original technical papers reflecting the most recent research and application results, and identify new challenges and ways forward for future research in NCM of various composites. The Special Issue will focus on advanced materials/composites and their NCM and machinability, but other relevant areas will also be considered. Papers covering the aforementioned important and timely topics will be particularly sought for by this Special Issue.

Therefore, prospective authors will be required to submit their cutting edge and state-of-the-art research outcomes of various studies on NCM of different types of composites. Relevant manuscripts on experimental, analytical, numerical, and/or finite element methods, including case studies, will be encouraged to meet and satisfy the demand of numerous researchers in the thriving field of composite machining technology.

Keywords

  • composites
  • non-conventional machining (NCM)
  • machining-induced damage (MID)
  • fibre reinforced polymeric (FRP)
  • machinability
  • machining
  • fracture mode/mechanism
  • parameter
  • damage characterisation/analysis
  • delamination

Published Papers (1 paper)

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Research

Article
A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates
Appl. Sci. 2021, 11(11), 4743; https://doi.org/10.3390/app11114743 - 21 May 2021
Viewed by 341
Abstract
Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the [...] Read more.
Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45° and 90° manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation. Full article
(This article belongs to the Special Issue Non-conventional Machining and Machinability of Composites)
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