Fibre reinforced thermoplastic polymer (FRTP) composites have been used for a wide range of engineering applications (e.g. in transport, construction, energy, etc) due to their excellent mechanical properties and ease of repair and recycling. In recent years, FRTP is increasingly deployed as an alternative to conventional thermoset carbon fibre reinforced epoxy (CF/epoxy) composites, for the purpose of reducing the carbon footprint and contributing to a sustainable manufacturing agenda. Machining of FRTP remains an indispensable process to achieve rapid parts assembly whilst meeting stringent geometric tolerances. However, due to the heterogeneous structure and high thermal sensitivity of FRTP, a range of machining-induced damages (such as matrix smearing, thermal degradation, delamination, burr and surface cavity) often occur, leading to concerns on machined parts quality and reliability. To date, composite machining studies have been mostly focused on conventional thermoset CF/epoxy and there is a lack of an up-to-date, in-depth review of the latest advancement concerning the machining of thermoplastic FRTP. This paper provides a state-of-the-art overview on the recent developments in FRTP machining over the past decade, with a particular emphasis on machining characteristics, damage mechanisms as well as the challenges facing such manufacturing process. The purpose is to present the composite manufacturing community with a timely update, which may guide and inspire further research and development for future FRTP manufacturing. 

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Process optimization of high machining efficiency and low surface defects for HSD milling UD-CF/PEEK with limited thermal effect

The surface roughness of carbon fiber-reinforced polymer (CFRP) components is extremely important because of the increasing demand for higher performance, reliability, and longer lifetime in aerospace and other manufacturing industries. However, the cutting mechanisms of CFRP are still unclear, which limits its formation mechanism prediction for surface roughness. Thus far, this study presents three action mechanisms in the CFRP machining process: accumulation bouncing on the matrix, impact effect on carbon fibers, and workpiece self-action. The workpiece self-action was reflected and calculated using the light rope model, which is new in CFRP machining. Furthermore, the formation mechanisms of surface roughness were first elucidated in the high-speed dry (HSD) milling of CFRP. An accurate surface roughness prediction model was theoretically formulated considering the kinematics, dynamics, and carbon fiber distribution. Surface roughness was expressed as the three-dimensional arithmetic mean height. The surface roughness prediction model was established and confirmed to have a high prediction accuracy of 90.05%, demonstrating that the distribution of carbon fibers was the main influencing factor of the surface roughness. Moreover, nonlinear regression analysis was used to clarify the effects of cutting parameters on the surface roughness, impact effect, and relationship between the surface roughness and impact effect. The study verified the feasibility of HSD milling CFRP, and it also provided guidance for breaking the low-speed machining limits by improving the machining process. 

Surface roughness prediction model in high-speed dry milling CFRP considering carbon fiber distribution

Composite light ropes model-based dynamics force prediction model of high speed dry milling UD-CF/PEEK considering size effect

Surface integrity optimization of high speed dry milling UD-CF/PEEK based on specific cutting energy distribution mechanisms effected by impact and size effect

A force model of high-speed dry milling CF/PEEK considering fiber distribution characteristics

The invention aims to provide a device capable of compensating for the error generated in the manufacturing, installing and working process, reducing the return difference and compensating for the error caused by abrasion and other factors. That is, a novel flexible compensation type gear robot speed reducer is provided. According to the speed reducer, the number of engaging teeth is increased, and the transmission precision is improved. A flexible pin wheel housing changes into an ellipse under the effects of an external involute gear, stretches in the center line direction of the external involute gear so as to become longer, becomes narrow in the vertical direction, becomes narrow gradually in the long diameter direction from the center, and is shortest at the two ends of the long diameter. Thus, a gear which cannot achieve engaging when the pin wheel housing does not deform can achieve engaging after the pin wheel housing deforms and becomes narrow, and therefore the number of theengaging teeth of the speed reducer is increased, and the transmission precision is improved.

Novel flexible compensation type gear robot speed reducer

The present invention discloses an adjustment device for RV reducer return difference that compensates for the return difference due to RV retarder manufacturing, installation error, etc in a manner that the eccentric distance of a crankshaft is adjusted. The design concept of the present scheme is as follows: due to the limit of machining accuracy and assembly accuracy during manufacturing and processing, a cycloidal gear still has a mesh clearance after profiling, when gyratory motion occurs, return difference is generated, and a plurality of errors accumulate; when the crankshaft is assembled, the maximum error is formed by accumulation, so that the eccentric distance increases or decreases due to the error; and when the eccentric distance is greater than assembly needs, interference occurs, thus affecting assembly, when the eccentric distance is smaller, a clearance is formed between the cycloidal gear and a needle gear, thus affecting transmission accuracy, and the above conditions can be effectively changed by adjusting the eccentric distance.

Adjustment device for RV retarder return difference

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A force model of high-speed dry milling CF/PEEK considering fiber distribution characteristics

Novel flexible compensation type gear robot speed reducer

Adjustment device for RV retarder return difference