Experimental and numerical investigation on the role of double helical angle tool in trimming CFRP aerospace composites

Abstract

Carbon fiber reinforced polymers (CFRP) is extensively used in aircraft structure due to its superior physical and mechanical properties. Since it is necessary to perform the edge-trimming operation for removal of the remaining materials after the curing to net shape, it is critical to study the role of tool geometry with contemplation to improve the edge-trimmed quality. The present research aims to investigate the effects of left and right helical angle in edge-trimming CFRP composite with the help of computational statistical modelling and numerical simulation. Based on the response surface methodology (RSM) and analysis of variance (ANOVA) results, it was found that both left and right helix are statistically significant on surface roughness and unintentionally blended to form segmented helical edge. Furthermore, the observation on the simulation results revealed that CFRP plies experienced two directions of forces which were downward forces by effects of right helix and upward forces by effects of left helix. Additionally, the left helix serves as a secondary material remover which removed the residue material left by right helix. This study provides an information that can offer great prospective for new optimum tool design.