Carbon fibre and carbon fibre reinforced polymer matrix composites (CFRPs) are important lightweight materials for aerospace, automotive, rail transport, infrastructure, and renewable energy applications. This paper provides a comprehensive review on the history of carbon fibres and carbon fibre composites, the current global CFRPs consumption, and trends for future developments in the aerospace, wind turbine, automotive, pressure vessels, sports and leisure, and construction sectors. The history of carbon fibres and CFRPs is discussed over four representative periods including their early development (1950–60's), growth of carbon fibre composites industry (1970–80's), major adoption of carbon fibre composites (the first wave, 1990–2000's), and expanded use of carbon fibre composites (the second wave, 2010's and beyond). Despite a 37% decline of carbon fibre consumption in the aerospace industry in 2021 caused by COVID-19, the global CFRP demand was around 181 kt which more than doubled its value in 2014. There is tangible projected increase over the next five years and the demand for CFRPs is expected to reach 285 kt in 2025, mainly attributed from the fast expansion of non-aerospace industries such as the wind energy sector. Lower cost carbon fibres (e.g., large tow) and associated manufacturing technologies are continually evolving. Finally, the implications of emerging materials and manufacturing methods in conjunction with recycling and reuse for carbon fibre composites are discussed. 

Past, present and future prospective of global carbon fibre composite developments and applications

Carbon fibre reinforced polymer (CFRP) composites have excellent specific mechanical properties, these materials are therefore widely used in high-tech industries like the automobile and aerospace sectors. The mechanical machining of CFRP composites is often necessary to meet dimensional or assembly-related requirements; however, the machining of these materials is difficult. In an attempt to explore this issue, the main objective of the present paper is to review those advanced cutting tools and technologies that are used for drilling carbon fibre reinforced polymer composites. In this context, this paper gives a detailed review and discussion of the following: (i) the machinability of CFRP including chip removal mechanisms, cutting force, tool wear, surface roughness, delamination and the characteristics of uncut fibres; (ii) cutting tool requirements for CFRP machining; and (iii) recent industrial solutions: advanced edge geometries of cutting tools, coatings and technologies. In conclusion, it can be stated that advanced geometry cutting tools are often necessary in order to effectively and appropriately machine required quality features when working with CFRP composites.

Advanced cutting tools and technologies for drilling carbon fibre reinforced polymer (CFRP) composites: A review

Measuring and characterizing of surface roughness of machined surfaces of carbon fiber reinforced polymer (CFRP) composites are difficult due to the occurrence of special surface damages (delamination, uncut fibers, fiber pull-outs or micro-cracks, etc.). The main objective of the present study is to analyze the characteristics of surface roughness of machined unidirectional CFRP in detail. Numerous conventional drilling, helical milling, and edge trimming experiments were carried out with different cutting tools in order to analyze the influence of them on the average surface roughness (Ra), on the roughness depth (Rz) and on the Rz /Ra parameter. The surface roughness was measured by a Mitutoyo SJ-400 contact profilometer and an Alicona Infinite Focus confocal microscope. The usability of the contact profilometer was experimentally tested and compared its results with the results of the confocal microscope. Experimental results show that the contact profilometer is suitable for measuring surface roughness of CFRP, furthermore, values of Rz /Ra of drilled and edge trimmed surfaces of unidirectional CFRP are changing in a wide interval: from 5 to 14 μm/μm due to the special surface damages. Based on this research, the machinability analysis of CFRP is suggested to be extended to the analysis of the Rz /Ra parameter.

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Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

Machining of carbon fiber-reinforced polymers (CFRP) still remains a difficult procedure in the whole manufacturing process. One of the reasons is the cutting mechanism varies during machining, causing the inconsistency of surface integrity. This study intends to investigate the continuous variation of cutting mechanism and the induced cutting responses and damages. A novel experiment, with square and circular workpieces involved in cutting, was designed. A three-dimension micro-scale cutting simulation model was built. The experiment and simulation were combined to analyze the evolution and the correlation of cutting forces, machined surface roughness, sub-surface damage and the burr formation. The effects of rake angle and tool edge radius on chip formation and sub-surface damage were also presented. The conclusions are helpful to understand the damages generation during machining of CFRP.

Investigation of CFRP cutting mechanism variation and the induced effects on cutting response and damage distribution

Structural optimization method of multitooth cutter for surface damages suppression in edge trimming of Carbon Fiber Reinforced Plastics

Undesirable machining damages exist frequently in the conventional machining processes of CFRP, causing significant decline in the performance of CFRP components. For effectively suppressing various machining damages, this study aims to reveal the evolution laws of the fiber-matrix interface crack, which can be regarded as the origin of majority of the machining damages. In order to accurately and conveniently obtain the evolution laws determined by numerous coupled factors, the study is conducted through a combined method of experiments and machine-learning predictions. Specifically, orthogonal cutting experiments are conducted for analyzing the fiber-matrix interface crack’s types and depth, and upon these characteristics predictive models based on machine learning are established for acquiring sufficient data so that reliable evolution laws can be obtained. From the results, it is found that there are four evolution types in all and when “burrs and cracks” exist, the crack depth increases obviously, and both the evolution types and depth are mainly determined by the fiber cutting angle. According to this, preliminary optimization methods of machining CFRP are proposed. The conclusions of this study are beneficial to facilitate the development of high-quality and high-efficiency machining technologies of CFRP.

Evolution laws of fiber-matrix interface cracks in machining of carbon fiber reinforced polymer

The present invention belongs to the technical field of drilling tools in machining, and relates to a vertical-edge double-step sawtooth cutter for preparing high-quality holes of composite material and thereof hybrid stack structure The vertical-edge double-step sawtooth cutter for preparing high-quality holes of composite material and laminated structure thereof comprises three parts which are a major cutting edge region A, a minor cutting edge region B and a shank region C, wherein the minor cutting edge region B comprises a step vertical-edge region D and a sawtooth cutting region E The vertical-edge double-step sawtooth cutter for making high-quality holes of composite material and laminated structure thereof in the present invention has the step structure and the sawtooth structure which is distributed in the first step, has a recutting function at the inlet and a reverse cutting function at the outlet in the direction opposite to the main cutting motion and effectively inhibits damage such as inlet and outlet layering and burr of the composite material The cutter has the vertical edge structure distributed in the second step, and the angle of the second step is a negative value, thereby realizing chip breaking and crushing, reducing scratch to the upper-layer composite material and metal hole walls, removing the metal outlet burr and outlet burr of the composite material from roots and improving outlet quality of the metal and the composite material

Vertical blade double-ladder micro-tooth tool for perforating composite material and laminated structure thereof with high quality

The invention discloses a modular micro-pecking device for an automatic feeding drill, belongs to the field of cutting machining, and relates to the modular micro-pecking device of the automatic feeding drill for cutting machining. The modular micro-pecking device is composed of three portions of a spindle rotating sliding mechanism, a micro-pecking core mechanism and a reset mechanism. The spindle rotating sliding mechanism is composed of spindles, angular contact ball bearings, outer spline sleeves, inner spline cylinders, hole blocking rings and shaft blocking rings. The micro-pecking coremechanism is composed of thrust bearings, an outer spline nut, micro-pecking roller rings, inner spline sliding rings and undulating face nuts B5. The reset mechanism is composed of spring base nuts and springs. Modular design is adopted, three series and nine types of micro-pecking devices are arranged, and peck drilling action under different machining requirements are met. According to the modular micro-pecking device, the overall machining performance of the automatic feeding drill is improved, the chip breaking ability of drilling laminations is enhanced, accumulation of the cutting heatis reduced, the temperature of the cutting area is reduced, tool wear is effectively reduced, the quality of the hole walls of the laminations is improved, the tool life is prolonged, and practicability is achieved.

Modular micro-pecking device for automatic feeding drill

The invention belongs to the technical field of difficult-to-process material cutting and processing, and relates to a micro-tooth design method capable of realizing alternative cutting of left and right cutting edges. The method can realize a processing way of alternative cutting of a right rotary cutting edge and a left rotary cutting edge on different sections of an effective cutting part of amulti-edge milling cutter, and guarantees continuous action that CFRP surface layer fibres bear axial force in different directions, so that the purpose of restraining occurrence of burrs of a high-speed milling carbon fibre composite material surface layer is realized. Micro teeth of a peripheral edge are designed, and structure parameters of a milling cutter are determined, so that a design method capable of realizing alternative cutting of the left and right cutting edges is guaranteed. The micro-tooth design method has very good universality and a high engineering application value, and can finally realize high-speed, stable and effective processing under great cutting dosage of carbon fibre composite materials.

Micro-tooth design method capable of realizing alternative cutting of left and right cutting edges

The invention discloses a portable reverse cooling and dedusting integrated device, belongs to the field of cutting machining, and relates to a portable cooling and dedusting device capable of drilling structure parts of large curvature. The portable reverse cooling and dedusting integrated device is composed of six parts, namely a threaded drilling sleeve, a device main body, a sealing cover, multi-directional supporting and fixing structures, a negative pressure dust treatment part and a cooling liquid spraying part. The multi-directional supporting and fixing structures are symmetrically and uniformly distributed and composed of universal adjusting feet and angle adjusting mechanisms. The angle adjusting mechanisms are composed of positioning lifting lugs, fastening bolts and positioning bolts, wherein the positioning lifting lugs, the fastening bolts and the positioning bolts mutually cooperate to achieve angle changing and foot end fixing of the multi-directional supporting and fixing structures. The negative pressure dust treatment part is composed of a dust sucking connector, a dust sucking guiding pipe, a negative pressure dust collector and a collecting device. The portable reverse cooling and dedusting integrated device integrates the functions of dust sucking, reverse cooling, portability, quick station changing and the like, machining vibration of a long cutter is effectively reduced, independent change of the angles and lengths of the supporting structures is achieved, and complex structural surfaces can be positioned and machined in a high quality mode.

Portable reverse cooling and dedusting integrated device

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