Authors:

Min Yong Chun

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About Paper:

Additive manufacturing technology for fiber-reinforced thermoplastic composites is widely used in tooling applications, where the quality of the tool surface finish is of utmost importance. However, due to the heterogeneous nature of composites, improper machining parameters can result in more severe surface defects, such as fiber pull-out, fiber breakage, and melted polymer, compared to traditional metal tool machining processes. The primary objective of this research is to investigate the relationship between machining parameters, specifically surface speed (SFM) and feed rate (IPT), and the surface finish quality of additively manufactured fiber-reinforced thermoplastic composites. By studying these relationships, this research aims to identify optimal machining parameters for different composite materials. To assess each machining parameter, a thermal camera was used to measure temperatures of the part, tool, and chip during the machining process using various parameter settings. By optimizing cutting parameters, tool selection, and tool paths, manufacturers can minimize tool wear, reduce the frequency of tool changes, and improve overall tool life.Additionally, visual inspection and surface roughness testing were conducted to evaluate the surface finish quality of each test specimen. Two different carbon fiber-reinforced composites with distinct glass transition temperatures, namely Acrylonitrile Butadiene Styrene (ABS) and Polyethersulfone (PESU), were used as test specimens. This study serves as a valuable contribution and guide for operators seeking to effectively machine fiber-reinforced thermoplastic composites. The findings provide insights into optimizing the machining process and achieving desirable surface finish quality, thereby enhancing the overall efficacy of manufacturing composite tools.

Source:

Purdue University / 2023

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Co-authors:

Min Yong Chun