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Dr. Fermín Bañón
University of Cadiz, Mechanical Engineering and Industrial Design Department

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Journal article
Published: 18 August 2021 in International Journal of Mechanical Sciences
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The bonding of Carbon Fibre Reinforced ThermoPlastic composites (CFRTP) and steel is of great interest nowadays. Nevertheless, the difference in machinability between dissimilar materials requires a specific machining process. Abrasive water jet machining is a flexible and environmentally friendly technology that can machine dissimilar materials at the same time with good results. However, due to the characteristics of the process and materials, geometrical defects such as taper angle can be caused by the loss of kinetic energy. In this research, the study of the final geometry in abrasive waterjet machining of a hybrid CFRTP/Steel structure. A new methodology for the evaluation of taper angle with high accuracy has been developed through image processing. In addition, the surface quality in terms of Ra and Rz has been assessed. A potential-type trend between taper and hydraulic pressure has been established for both materials. Minimum taper values between 1.5° and 5° have been obtained for both materials and stacking configurations with a combination of a hydraulic pressure of 420 MPa, an abrasive mass flow of 225 g/min and a traverse speed of 50 mm/min.

ACS Style

Fermin Bañon; Alejandro Sambruno; Moises Batista; Bartolome Simonet; Jorge Salguero. Evaluation of geometrical defects in AWJM process of a hybrid CFRTP/Steel structure. International Journal of Mechanical Sciences 2021, 210, 106748 .

AMA Style

Fermin Bañon, Alejandro Sambruno, Moises Batista, Bartolome Simonet, Jorge Salguero. Evaluation of geometrical defects in AWJM process of a hybrid CFRTP/Steel structure. International Journal of Mechanical Sciences. 2021; 210 ():106748.

Chicago/Turabian Style

Fermin Bañon; Alejandro Sambruno; Moises Batista; Bartolome Simonet; Jorge Salguero. 2021. "Evaluation of geometrical defects in AWJM process of a hybrid CFRTP/Steel structure." International Journal of Mechanical Sciences 210, no. : 106748.

Original article
Published: 10 April 2021 in The International Journal of Advanced Manufacturing Technology
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The application of carbon fiber reinforced thermoplastic matrix composites (CFRTP) is constantly increasing in various industrial sectors due to their mechanical properties and advantages compared to thermoset matrix composite. Nevertheless, CFRTP machining generates a current problem due to the anisotropy of these materials, the difficulty of impregnation of the reinforcement in the matrix, and its low melting temperature. For this reason, the study of conventional operations such as milling to achieve geometries with a good surface quality and reduced cosmetic defects is a line of research of great interest. In this article, a comparison of five cutting tools with different geometries has been made in CFRTP milling. The surface quality and the formation of visual defects such as fiber pull-out have been evaluated for each tool and combination of cutting parameters. In this sense, 16.42 μm in terms of Rz is the minimum average value for the complete experiment obtained for a conventional tool (tool A). However, surface qualities in terms of Rz close to 20 μm and minimum cosmetic defects have been obtained with a hybrid tool (tool C) with −10° helix angle and 8 teeth with a combination of cutting parameters of 0.07 mm/tooth and 3000 rpm, being the most complete tool of the experiment.

ACS Style

Alejandro Sambruno; Fermin Bañon; Jorge Salguero; Bartolome Simonet; Moises Batista. Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions. The International Journal of Advanced Manufacturing Technology 2021, 114, 2515 -2526.

AMA Style

Alejandro Sambruno, Fermin Bañon, Jorge Salguero, Bartolome Simonet, Moises Batista. Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions. The International Journal of Advanced Manufacturing Technology. 2021; 114 (7-8):2515-2526.

Chicago/Turabian Style

Alejandro Sambruno; Fermin Bañon; Jorge Salguero; Bartolome Simonet; Moises Batista. 2021. "Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions." The International Journal of Advanced Manufacturing Technology 114, no. 7-8: 2515-2526.

Review
Published: 17 January 2021 in Metals
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The bonding of metallic alloys and composite materials in the form of a hybrid structure is a line of great interest for the current industry. The different machinability of both materials requires a specific machining process. Abrasive water-jet machining (AWJM) is an excellent technology for the simultaneous machining of both materials. However, defects at the micro and macro-geometric level have been detected in several scientific articles. In this review, a detailed study of the two main defects in metals, composite materials and hybrid structures has been developed. The conclusions of several scientific articles have been exposed for a better understanding of the topic in articles between 1984 and 2020. The influence of the cutting parameters on the reduction in kinetic energy of the water jet and the order of stacking of the materials in the hybrid structure is the main objective in order to minimize these defects. Cutting parameter optimization studies, predictive model proposals, process-associated defects and evaluation methodologies have been discussed. The aim of this article is to set a solid background on AWJM machining in hybrid structures and on the influence of cutting parameters on generated defects and machining strategies to obtain the best results at a macro and micro-geometric level.

ACS Style

Fermin Bañon; Alejandro Sambruno; Leandro González-Rovira; Juan Manuel Vazquez-Martinez; Jorge Salguero. A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials. Metals 2021, 11, 164 .

AMA Style

Fermin Bañon, Alejandro Sambruno, Leandro González-Rovira, Juan Manuel Vazquez-Martinez, Jorge Salguero. A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials. Metals. 2021; 11 (1):164.

Chicago/Turabian Style

Fermin Bañon; Alejandro Sambruno; Leandro González-Rovira; Juan Manuel Vazquez-Martinez; Jorge Salguero. 2021. "A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials." Metals 11, no. 1: 164.

Journal article
Published: 21 July 2020 in Metals
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The joining of dissimilar materials in a hybrid structure is a line of research of great interest at present. Nevertheless, the machining of materials with different machinability requires specific processes capable of minimizing defectology in both materials and achieving a correct surface finish in terms of functional performance. In this article, abrasive water jet machining of a hybrid carbon fiber-reinforced thermoplastics (CFRTP)/Steel structure and the generated surface finish are studied. A parametric study in two stacking configurations (CFRTP/Steel and Steel/CFRTP) has been established in order to determine the range of cutting parameters that generates the lowest values in terms of arithmetic mean roughness (Ra) and maximum profile height (Rz). The percentage contribution of each cutting parameter has been identified through an ANOVA analysis for each material and stacking configuration. A combination of 420 MPa hydraulic pressure with an abrasive mass flow of 385 g/min and a travel speed of 50 mm/min offers the lowest Ra and Rz values in the CFRTP/Steel configuration. The stacking order is a determining factor, obtaining a better surface quality in a CFRTP/Steel stack. Finally, a series of contour diagrams relating surface quality to machining conditions have been obtained.

ACS Style

Fermin Bañon; Bartolome Simonet; Alejandro Sambruno; Moises Batista; Jorge Salguero. On the Surface Quality of CFRTP/Steel Hybrid Structures Machined by AWJM. Metals 2020, 10, 983 .

AMA Style

Fermin Bañon, Bartolome Simonet, Alejandro Sambruno, Moises Batista, Jorge Salguero. On the Surface Quality of CFRTP/Steel Hybrid Structures Machined by AWJM. Metals. 2020; 10 (7):983.

Chicago/Turabian Style

Fermin Bañon; Bartolome Simonet; Alejandro Sambruno; Moises Batista; Jorge Salguero. 2020. "On the Surface Quality of CFRTP/Steel Hybrid Structures Machined by AWJM." Metals 10, no. 7: 983.

Original article
Published: 14 April 2020 in The International Journal of Advanced Manufacturing Technology
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Carbon fiber-reinforced thermoplastics (CFRTP) have great interest nowadays due to their excellent mechanical properties and lightness. However, in opposition to thermoset matrix composites, there is a lake in the research about machining processes of these materials. Their low glass transition temperature is a handicap when conventional machining is used. An alternative is abrasive water jet machining (AWJM) because it does not cause thermal damage. However, the surface quality produced by this process must be studied and related to the cutting parameters. This article studies the surface quality generated by water jet machining in a low melting point thermoplastic matrix composite material. The kind of thermoplastic used is a TPU (polyurethane). The combination of a high-strength material (carbon fiber) with a low-strength material (thermoplastic matrix) makes machining difficult and can generate a poor surface finish. The influence of cutting parameters has been evaluated through an ANOVA analysis. A mathematical model that relates the surface quality with the cutting parameters has been established by means of a response surface methodology (RSM). The combination of a hydraulic pressure of 250 MPa with a traverse speed of 300 mm/min and an abrasive mass flow of 170 g/min produces the best surface quality. Finally, the main flaws when CFRTP is water jet machined have also been identified.

ACS Style

Fermin Bañon; Alejandro Sambruno; Moises Batista; Bartolome Simonet; Jorge Salguero. Study of the surface quality of carbon fiber–reinforced thermoplastic matrix composite (CFRTP) machined by abrasive water jet (AWJM). The International Journal of Advanced Manufacturing Technology 2020, 107, 3299 -3313.

AMA Style

Fermin Bañon, Alejandro Sambruno, Moises Batista, Bartolome Simonet, Jorge Salguero. Study of the surface quality of carbon fiber–reinforced thermoplastic matrix composite (CFRTP) machined by abrasive water jet (AWJM). The International Journal of Advanced Manufacturing Technology. 2020; 107 (7-8):3299-3313.

Chicago/Turabian Style

Fermin Bañon; Alejandro Sambruno; Moises Batista; Bartolome Simonet; Jorge Salguero. 2020. "Study of the surface quality of carbon fiber–reinforced thermoplastic matrix composite (CFRTP) machined by abrasive water jet (AWJM)." The International Journal of Advanced Manufacturing Technology 107, no. 7-8: 3299-3313.

Journal article
Published: 22 February 2020 in Metals
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Surface modification by different technologies prior to joining operations or improving tribological properties is a point of great interest. Improving surface activation by increasing the roughness of the metal is a relationship that is becoming more defined. In turn, an increase in surface wettability by evaluating contact angles indicates surface activation by obtaining a high surface free energy. Technologies such as shot blasting and laser surface texturing (LST) have generated several scientific studies where they have identified the influence of parameters on the formation of rough surfaces with defined patterns. However, the application of abrasive water jet texturing (AWJT) has been little studied as an alternative. This article compares these technologies in the texturing of a carbon steel s275 in order to identify the relationship between surface quality and surface activation. It has been determined that AWJT produces the highest Rt values close to 64 µm with a cross feed of 0.45 mm and a traverse speed of 5000 mm/min. Furthermore, LST obtains the best values of free surface energy by combining a power of 20 W with a frequency of 20 kHz and a sweeping speed of 10 mm/s. Finally, contour diagrams have been obtained which relate these variables to the texturing parameters.

ACS Style

Fermin Bañon; Alejandro Sambruno; Moises Batista; Bartolome Simonet; Jorge Salguero. Surface Quality and Free Energy Evaluation of s275 Steel by Shot Blasting, Abrasive Water Jet Texturing and Laser Surface Texturing. Metals 2020, 10, 290 .

AMA Style

Fermin Bañon, Alejandro Sambruno, Moises Batista, Bartolome Simonet, Jorge Salguero. Surface Quality and Free Energy Evaluation of s275 Steel by Shot Blasting, Abrasive Water Jet Texturing and Laser Surface Texturing. Metals. 2020; 10 (2):290.

Chicago/Turabian Style

Fermin Bañon; Alejandro Sambruno; Moises Batista; Bartolome Simonet; Jorge Salguero. 2020. "Surface Quality and Free Energy Evaluation of s275 Steel by Shot Blasting, Abrasive Water Jet Texturing and Laser Surface Texturing." Metals 10, no. 2: 290.

Journal article
Published: 13 December 2019 in Materials
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Carbon fiber-reinforced thermoplastics (CFRTPs) are materials of great interest in industry. Like thermosets composite materials, they have an excellent weight/mechanical properties ratio and a high degree of automation in their manufacture and recyclability. However, these materials present difficulties in their machining due to their nature. Their anisotropy, together with their low glass transition temperature, can produce important defects in their machining. A process able to machine these materials correctly by producing very small thermal defects is abrasive waterjet machining. However, the dispersion of the waterjet produces a reduction in kinetic energy, which decreases its cutting capacity. This results in an inherent defect called a kerf taper. Also, machining these materials with reduced thicknesses can increase this defect due to the formation of a damage zone at the beginning of cut due to the abrasive particles. This paper studies the influence of cutting parameters on the kerf taper generated during waterjet machining of a thin-walled thermoplastic composite material (carbon/polyurethane, C/TPU). This influence was studied by means of an ANOVA statistical analysis, and a mathematical model was obtained by means of a response surface methodology (RSM). Kerf taper defect was evaluated using a new image processing methodology, where the initial and final damage zone was separated from the kerf taper defect. Finally, a combination of a hydraulic pressure of 3400 bar with a feed rate of 100 mm/min and an abrasive mass flow of 170 g/min produces the minimum kerf taper angle.

ACS Style

Alejandro Sambruno; Fermin Bañon; Jorge Salguero; Bartolome Simonet; Moises Batista. Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU. Materials 2019, 12, 4192 .

AMA Style

Alejandro Sambruno, Fermin Bañon, Jorge Salguero, Bartolome Simonet, Moises Batista. Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU. Materials. 2019; 12 (24):4192.

Chicago/Turabian Style

Alejandro Sambruno; Fermin Bañon; Jorge Salguero; Bartolome Simonet; Moises Batista. 2019. "Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU." Materials 12, no. 24: 4192.

Journal article
Published: 06 January 2019 in Materials
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The use of adhesive layers can improve the properties and reduce the defects produced in the interfaces. This provides adherence to the structure, adapting the joining surfaces and avoiding spaces between the layers. However, the presence of the adhesive can potentiate the defects caused during drilling. In turn, a loss of adhesive in the interface can occur during machining affecting the final structure. This work has followed a conventional OSD strategy in CFRP and UNS A92024 aluminium sheet stacking with adhesive. A series of dry drilling tests have been developed with different cutting conditions and new noncoated WC-Co helical cutting tools. Analysis of Variance (ANOVA) statistical analyses and surface response models have been applied to determine the mechanical behaviour in the holes. For this purpose, the dimensional deviation, surface quality, and adhesive loss in the interface in relation to the number of holes have been considered. A combination of cutting parameters that minimizes the evaluated defects has been found. Diametric deviations and surface qualities below 2% and 3.5 µm have been measured in the materials that make up the stack with cutting speeds higher than 140 m/min and feed rates between 200 and 250 mm/min. However, the greatest adhesive losses occur at high cutting speeds.

ACS Style

Fermin Bañon; Alejandro Sambruno; Sergio Fernandez-Vidal; Severo Raul Fernandez-Vidal. One-Shot Drilling Analysis of Stack CFRP/UNS A92024 Bonding by Adhesive. Materials 2019, 12, 160 .

AMA Style

Fermin Bañon, Alejandro Sambruno, Sergio Fernandez-Vidal, Severo Raul Fernandez-Vidal. One-Shot Drilling Analysis of Stack CFRP/UNS A92024 Bonding by Adhesive. Materials. 2019; 12 (1):160.

Chicago/Turabian Style

Fermin Bañon; Alejandro Sambruno; Sergio Fernandez-Vidal; Severo Raul Fernandez-Vidal. 2019. "One-Shot Drilling Analysis of Stack CFRP/UNS A92024 Bonding by Adhesive." Materials 12, no. 1: 160.

Journal article
Published: 01 January 2019 in Procedia Manufacturing
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The application of Carbon Fiber Reinforced ThermoPlastic matrix composites (CFRTP) is constantly increasing today. They have an excellent weight-to-mechanical properties ratio and in comparison to thermostable matrix composites their recycling efficiency is higher. However, these must be machined to obtain complex geometries that perform their function. The abrasive water jet machining (AWJM) is a process free of thermal defects, avoiding to reach the glass transition temperatures of the thermoplastic matrix. At the same time, it can generate very good surface quality results. This article focuses on the influence of cutting parameters on the AWJM machining of a CFRTP through surface quality. The surface quality has been evaluated in three different regions of the thickness generated. Finally, some contour diagrams obtained allow to predict the surface quality with in the cutting parameters used.

ACS Style

Fermin Bañon; Alejandro Sambruno; Raul Ruiz Garcia; Jorge Salguero; Pedro F. Mayuet. Study of the influence of cutting parameters on surface quality in AWJM machining of thermoplastic matrix composites. Procedia Manufacturing 2019, 41, 233 -240.

AMA Style

Fermin Bañon, Alejandro Sambruno, Raul Ruiz Garcia, Jorge Salguero, Pedro F. Mayuet. Study of the influence of cutting parameters on surface quality in AWJM machining of thermoplastic matrix composites. Procedia Manufacturing. 2019; 41 ():233-240.

Chicago/Turabian Style

Fermin Bañon; Alejandro Sambruno; Raul Ruiz Garcia; Jorge Salguero; Pedro F. Mayuet. 2019. "Study of the influence of cutting parameters on surface quality in AWJM machining of thermoplastic matrix composites." Procedia Manufacturing 41, no. : 233-240.