A model based material removal simulation for vacuum suction blasting of composites
Tóm tắt
Automated scarfing of carbon reinforced plastic (CFRP) layers is on its way to support commercial aircraft repair. In the industry, still, the manual scarfing operation is the qualified method. However, automated techniques as milling, laser removal and water jet cutting are in development and showed already good results. Another promising method is vacuum suction blasting (VSB) that was until now in particular used for the roughening of surfaces before adhesive bonding. To find the right adjustment for the parameters many experiments would be necessary accordingly to different CFRP parts with changing layer thicknesses. Simulation is a way to avoid this and to predict the removal result and the settings for the machining parameters. The VSB model uses a pixel method dividing the simulated part surface into smaller volume elements. Experimental data of VSB static blasting spots are the basic for the source matrix. The simulation feeds the matrix with the blasted depth and removal volume for different blasting times. A shifting of columns of the source matrix in the blasting movement direction simulates the movement of the blasting nozzle on the work piece surface. With this, the model can also predict the nozzle feed to remove exactly one complete layer for each scarfing step. In addition, it visualizes the seamless overlapping distance between two blasted tracks. With further adjustments, the model will predict the dynamic removal for varying input parameters such as negative pressure and nozzle distance or blasting agent.
Từ khóa
Tài liệu tham khảo
McIlhagger AT, Archer E. Polymer composites in the aerospace industry. Manuf process compos mater compon aerospace appl. 2014;3:53.
Wang CH, Duong CN. Bonded joints and repairs to composite airframe structures. Repair manuf process. 2016;9:243–64.
Encinas N, Oakley BR, Belcher MA. Surface modification of aircraft used composites for adhesive bonding. Int J Adhes Adhes. 2014;50:157–63.
Halliwell S. Repair of Fibre Reinforced Polymer (FRP) Structures National Composites Network: Best Practice Guide. NetComposites. http://www.compositesuk.co.uk. 2018; 1–33
Brieskorn L, Hintze W. Automated removal of carbon fiber reinforced plastic layers for the repair by adhesive bonding. Proc Ins Mechan Eng Part G J Aeros Eng. 2020;234(13):2011–22.
Hocheng H. Machining technology for composite materials: principles and practice. Cambridge: Woodhead Publishing Limited; 2011.
Holzhüter D. Pototzky A. Hühne C.Automated Scarfing Process for Bonded Composite Repairs. Adaptive, tolerant and efficient composite structures.2012; 297–307
Hintze W, Hartmann D, Schubert U. Stirnfräsen von CFK zur Fügeflächenherstellung und Reparaturvorbereitung. ZWF Z für Wirtschaf Fabrikbetrieb. 2012;107(6):462–6.
Holtmannspötter J. On the fabrication and automation of reliable bonded composite repairs. J Adhes. 2015;91(1–2):39–70.
Freese J, Holtmannspötter J. End milling of Carbon Fiber Reinforced Plastics as surface pretreatment for adhesive bonding – effect of interlaminar damages and particle residues. J Adhes. 2018;1:19.
Holtmannspötter J, Höfer P. End milling as a surface pretreatment for adhesive bonding of CFRP – new approaches for root cause identification of reduced bond line performance. Procedia CIRP. 2019;85:230–6.
Fischer F, Romoli L, Kling R. Laser-based repair for carbon fiber reinforced composites. Compos Sci Eng Machin Technol Compos Mater. 2012;12:309–30.
Harder S, Schmutzler H, Freese J, Holtmannspötter J. Effect of infrared laser surface treatment on the morphology and adhesive properties of scarfed CFRP surfaces. Compos Part A Appl Sci Manuf. 2019;121:299–307.
Takahashi K, Tsukamoto M, Masuno S. Heat conduction analysis of laser CFRP processing with IR and UV laser light. Compos A Appl Sci Manuf. 2016;84:114–22.
Hintze W. Cordes M. Geis T. Laser Scored Machining of Fiber Reinforced Plastics to Prevent Delamination. In: 16th Machining Innovations Conference for Aerospace Industry - MIC 2016 Procedia Manufacturing. 2016; 6: 1–8
Holder D, Boley S, Weber R. In-process determination of fiber orientation for layer accurate laser ablation of CFRP. Sci Direct. 2018;74:557.
Fischer F, Kreling S, Blass D. Laser material machining of CFRP – an option for damage-free and flexible CFRP processing? Machinabil Fibre-Reinf Plastics. 2015;1:1–30.
Cénac F. Collombet F. Zitoune R. Abrasive-water-jet blind-machining of polymer matrix composite materials. In: Proceedings of ECCM 13. 2008; 1: 1728
Dunsky C, Tacheron P, Hashish M. Waterjet techniques for composite material jet engine component repair. QUEST Technical Rep. 1996;716:1–41.
Kreling S, Blass D, Dilger K. Klebvorbehandlung von FVK durch Unterdruckstrahlen – sauber und prozesssicher. Leichtbau-Technol im Automob ATZ/MTZ Fachbuch. 2014;1:101–8.
Boerio FJ, Roby B, Dillingham RG, Bossi RH, Crane RL. Effect of grit-blasting on the surface energy of graphite/epoxy composites. J Adhes. 2006;82(1):19–37.
Achtsnick M, Hoogstrate AM, Karpuschewski B. Advances in high performance micro abrasive blasting. CIRP Ann. 2005;54:281–4.
Karpuschewski B, Hoogstrate AM, Achtsnick M. Simulation and improvement of the micro abrasive blasting process. CIRP Ann. 2004;53:251–4.
Fu X, Song K, Kim DM, et al. Geometrical simulation model for milling of carbon fiber reinforced polymers (CFRP). Int J Precis Eng Manuf. 2022;23(11):1237–60.
Dubusta N, Pinab C, Ghadbeigi H. FE modelling of CFRP machining- prediction of the effects of cutting edge rounding. Procedia CIRP. 2019;82:59–64.
Xua LY, Lu JR. Removal mechanism of CFRP by laser multi direction interaction. Opt Laser Technol. 2021;143:107–281.
Keuntjea J, Mrzljak S. Macroscopic simulation model for laser cutting of carbon fibre reinforced plastics. Procedia CIRP. 2022;111:496–500.
Ohkuboa T, Sato Y. Three-dimensional numerical simulation during laser processing of CFRP. Appl Surf Sci. 2017;417:104–7.
Abdelhameed Y, Hassan AI, Kaytbay S. A user-friendly finite element model for radial mode abrasive waterjet turning. J Eng Manuf. 2021;235(12):1904.
Mudragada R, Mishra SS. Effect of blast loading and resulting progressive failure of a cable-stayed bridge. SN Appl Sci. 2021;3:322.
Biermann D. et al. Simulation based analysis and optimisation of the cutting edge micro shape for machining of nickel-base alloys, In: Conference on Intelligent Computation in Manufacturing Engineering. 2017.pp 284–289