Machining of Polymer Composites (eBook)

Preface 6
Contents 8
1 Introduction to Polymer Composites 12
1.1 Definitions and Classification 13
1.2 Advantages and Limitations 14
1.3 Applications 16
1.4 Constituent Materials 18
1.5 Material Forms and Manufacturing 27
1.6 Properties of Composites 37
1.7 Summary 42
Review Questions and Problems 44
References 45
2 Conventional Machining Operations 47
2.1 Requirements for Machining FRPs 48
2.2 Turning 49
2.3 Single Point Cutting Tools 51
2.4 Milling and Trimming 52
2.5 Drilling 58
2.6 Abrasive Cutting 61
2.7 Surface Finish 65
2.8 Summary 69
Review Questions and Problems 70
References 72
3 Mechanics of Chip Formation 73
3.1 Fundamental Considerations 74
3.2 Machining of Polymers 81
3.3 Machining of Unidirectional FRPS 83
3.4 Machining of Multidirectional Laminates 99
3.5 Modeling of the Chip Formation Process 101
3.6 Summary 114
Review Questions and Problems 116
References 119
4 Tool Materials and ToolWear 121
4.1 Tool Materials for Machining FRPs 121
4.2 ToolWear 131
4.3 Summary 147
Review Questions and Problems 148
References 150
5 Conventional Machining of FRPs 152
5.1 Machinability of FRPs 152
5.2 Turning of FRPs 154
5.3 Milling and Trimming of FRPs 169
5.4 Drilling of FRPs 196
5.5 Abrasive Machining and Grinding 219
5.6 Summary 235
Review Questions and Problems 238
References 241
6 Nontraditional Machining of FRPs 245
6.1 AbrasiveWaterjet Machining 245
6.2 Laser Machining 268
6.3 Electrical Discharge Machining 284
6.4 Summary 293
Review Questions and Problems 295
References 297
7 Health and Safety Aspects in Machining FRPs 300
7.1 Hazard Sources and Routes of Exposure 301
7.2 Dust Generation in Dry Machining 305
7.3 Aerosol Emissions in Laser Machining 307
7.4 Workplace Controls 309
7.5 Summary 311
References 313
Index 315