Effect of Cutting Fluid Delivery Method on Ultrasonic Assisted Edge Trimming of Multidirectional CFRP Composites at Different Machining Conditions

Edge trimming of CFRP composite laminates, using abrasive tools, is needed as a finishing operation for better quality and dimensional accuracy. Fiber delamination and resin burning are the major difficulties associated with traditional machining processes of CFRP. Although dry cutting is preferable for cutting CFRP which not absorb cutting fluid and eliminate the need for subsequent cleaning, increasing cutting temperature leads to degradation, smearing, and burning of epoxy resin. This paper investigates the effect of different fluid delivery methods (MQL/flood) on ultrasonic assisted machining (UAM) of multidirectional CFRP laminates using diamond abrasive tools at different cutting conditions. The process parameters studied were cutting speed, feed rate, radial depth of cut, and cooling modes. Cutting forces, surface integrity, and bouncing-back effect were the output responses of this study. Statistical analysis was conducted to study the effect of each factor on the performance characteristics. The results showed that flood coolant provide better results than MQL. However, MQL responses still comparable with flood coolant. The conditions that gave the best responses of MQL were determined which can be utilized for near dry cutting demands.