Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 30578
Effect of Ply Orientation on Roughness for the Trimming Process of CFRP Laminates

Authors: Jean François Chatelain, Imed Zaghbani, Joseph Monier


The machining of Carbon Fiber Reinforced Plastics has come to constitute a significant challenge for many fields of industry. The resulting surface finish of machined parts is of primary concern for several reasons, including contact quality and impact on the assembly. Therefore, the characterization and prediction of roughness based on machining parameters are crucial for costeffective operations. In this study, a PCD tool comprised of two straight flutes was used to trim 32-ply carbon fiber laminates in a bid to analyze the effects of the feed rate and the cutting speed on the surface roughness. The results show that while the speed has but a slight impact on the surface finish, the feed rate for its part affects it strongly. A detailed study was also conducted on the effect of fiber orientation on surface roughness, for quasi-isotropic laminates used in aerospace. The resulting roughness profiles for the four-ply orientation lay-up were compared, and it was found that fiber angle is a critical parameter relating to surface roughness. One of the four orientations studied led to very poor surface finishes, and characteristic roughness profiles were identified and found to only relate to the ply orientations of multilayer carbon fiber laminates.

Keywords: Aerospace, Composites, roughness, Detouring

Digital Object Identifier (DOI):

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2193


[1] Davim J.P., Reis P., Antonio C.C.. "A Study on Milling of Glass Fiber Reinforced Plastics Manufactured by Hand-lay up Using Statistical Analysis", Composite Structures, Vol. 64, No. 3, pp. 493-500, 2004.
[2] Davim J.P., Reis P., "Damage and dimensional precision on milling carbon fiber-reinforced plastics using design experiments", Journal of Materials Processing Technology, Vol. 160 No. 2, pp. 160-167, 2005.
[3] Palanikumar K., "Cutting Parameters Optimization for Surface Roughness in Machining of GFRP Composites using Taguchi-s Method", Journal of Reinforced Plastics and Composites, Vol. 25, No. 16, pp. 1739-1751, 2006.
[4] Palanikumar K., "Surface Roughness Model for Machining Glass Fiber Reinforced Plastics by PCD Tool using Fuzzy Logics", Journal of Reinforced Plastics and Composites, Vol. 28 No.18, pp. 2273-2286, 2009.
[5] Rajasekaran T., Vinayagam B.K., Palanikumar K., Prakash S., "Influence of Machining Parameters on Surface Roughness and Material Removal Rate in Machining Carbon Fiber Reinforced Polymer Material", Frontiers in Automobile and Mechanical Engineering (FAME), p. 75, 2010.
[6] Eriksen E., "Influence from Production Parameters on the Surface Roughness of a Machined Short Fiber Reinforced Thermoplastic", International Journal of Machine Tools and Manufacture, Vol. 39, pp. 1611-1618, 1999.
[7] Palanikumar K., Davim J.P., "Mathematical model to predict tool wear on the machining of glass fibre reinforced plastic composites", Materials & Design, Vol. 28, No. 7, pp. 2008-2014, 2007.
[8] Sarma P.M.M.S., Karunamoorthy L., Palanikumar K., Surface roughness parameters evaluation in machining GFRP composites by PCD tool using digital image processing, Journal of Reinforced Plastics and Composites, Vol. 28, No. 13, pp. 1567-1585, 2009.
[9] Jahromi A.S., Gudimani G., Kalla D.K., Bahr B., "Effect of High RPM Machining and Fiber Orientation On Subsurface Damage in Machining of Unidirectional Composites", SAMPE 2011 State of the Industry: Advanced Materials, Applications, and Processing Technologies, Long- Beach, Ca., 2011.
[10] Chatelain J.-F., Zaghbani I., "Effect of Tool Geometry. Special Features on Cutting Forces of Multilayered CFRP Laminates", Proc. of the 4th Int. Conference on Manufacturing Engineering, Quality and Production Systems, MEQAPS`11, Barcelona, Spain, pp. 85-90, 2011.
[11] Kalla D.,Sheikh-Ahmad J., Twomey J., "Prediction of cutting forces in helical end milling fiber reinforced polymers", Journal of Machine Tools and Manufacture, vol. 50, no. 10, pp. 882-891, 2010.