Optimization of machining parameters in grinding of unidirectional carbon fiber reinforced composites by Response Surface Method

Today, the usage of composite materials in various industries such as aerospace, transportation, construction, etc. has increased. Therefore, an adequate understanding of the production processes and assembly of these materials is inevitable. Machining is one of the common processes in assembling composite parts. This process includes two categories of traditional and non-traditional machining processes that grinding is one of the traditional methods. Grinding is one of the applicable machining processes for the finishing of composite parts. Many parameters such as feed rate, depth of cut, tool geometry, fiber direction, and abrasive particles material and size are effective on the machined surface. In this study, the effect of grinding parameters including feed rate, depth of cut, abrasive particles size, and fiber orientation on the surface quality of Carbon Fiber Reinforced Polymer (CFRPs) has been evaluated. The experiments were designed by Response Surface Method (RSM) in Minitab software V.19. The results showed that abrasive particle's size and depth of cut are the most effective parameters on the machined surface roughness. The feed rate and fiber direction are of secondary importance, respectively. Also, the scanning electron microscopy (SEM) images confirm these results. Finally, it was suggested to use 50µm of the depth of cut, 200mm/min of feed rate, perpendicular to fiber direction and course abrasive particle to achieve a roughness of less than 5µm.