Progressive scheme via eccentric rotation of abrasive cutting edges for minimum damage machining of fibre reinforced polymer composites: Micro-mechanics and performance aspects

Abstract

Progressive-intermittent cutting using controlled eccentricity to the rotation of grinding wheel, referred to as “eccentric sleeve grinding”, is projected as one of the promising methodologies for minimising damages while machining Fibre Reinforced Polymer Composites (FRPs). This paper unveils the micromechanics of eccentric sleeve grinding through a detailed investigation of the progressive interaction of abrasive cutting edges with a fibre-matrix system. The theoretical model in this paper provides a comprehensive understanding of the contact/cutting behaviour of abrasive grains located on a wheel that rotates with fine eccentricity during its interaction with the matrix as well as fibres embedded in the matrix. A seven-grit experimental analogy of progressive cutting with the assessment of elastic and brittle modes of material removal, supplemented with the analysis of grinding force and surface micrographs, is a unique contribution to the work. Defect volume estimation using X-ray tomography, residual stress measurement using Raman Spectroscopy, and the hypothesis of skin level defects have also been discussed to provide a deeper insight into the micro mechanism of eccentric sleeve grinding.