Mechanical behavior of carbon fiber-reinforced plastic during rotary ultrasonic machining

This paper presents an investigation into the machining of CFRP composites using rotary ultrasonic machining. The study aims to analyze how various process parameters influence machining performance and to identify the optimal value of cutting force. The design approach employed isolates the effects of individual characteristics and explores the interactions between them. The results of this study reveal a nuanced interplay between the investigated parameters and the mechanical behavior of carbon fiber-reinforced plastic (CFRP) during rotary ultrasonic machining (RUM). Notably, variations in vibration amplitude (VA), tool rotation speed (TRS), and feed rate (Fr) significantly influenced the cutting force exerted on the CFRP material. Surprisingly, while both VA and TRS exhibited noticeable effects on the machining process, the feed rate emerged as the predominant factor in determining optimal cutting force levels. Specifically, the data illustrate that higher feed rates led to reduced cutting forces, indicating improved machinability. This unexpected inverse relationship prompts a reconsideration of traditional assumptions about the influence of process parameters on CFRP machining. The outcomes suggest that a strategic emphasis on feed rate adjustment can mitigate cutting forces, potentially enhancing the overall efficiency and quality of CFRP machining operations. These findings carry implications for industries reliant on CFRP components, such as aerospace and automotive sectors, offering a practical guide for optimizing machining processes and advancing the broader understanding of CFRP behavior under RUM conditions. The observed trends also open avenues for further research into the intricate dynamics of material removal in composite structures.