Xiao Liang Jin
Relevant Degree Programs
Affiliations to Research Centres, Institutes & Clusters
Surface integrity in vibration assisted machining process.
Surface texturing process.
Chip formation stability in high-speed machining process.
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Graduate Student Supervision
Master's Student Supervision (2010 - 2020)
Carbon fiber reinforced polymer (CFRP) composites have been widely used in aerospace, aviation, and automotive industries due to their high strength/stiffness-to-weight ratios, high temperature resistance and corrosion resistance. CFRP components are usually produced in near net-shape, and cutting operations such as drilling, slot milling, and edge trimming are required to remove excessive materials and fulfill the geometry and surface quality requirements of the final parts. Practical cutting operations are in the form of oblique and sequential cutting at the tool edge. Different from metal cutting, the material removal mechanism and surface quality are highly dependent on the fiber orientation in cutting CFRP materials. This thesis presents a 3-D finite element model of oblique cutting of unidirectional CFRP. The effects of the fiber orientation and oblique angles on the chip formation, cutting forces, and subsurface damage are simulated and analyzed. It is found that the out-of-plane force and the depth of subsurface damage increase with the oblique angle in all fiber orientation angles except 0°. To represent the nature of sequential cutting, a second cut on the machined material with existing damages and residual stresses due to previous cutting is simulated. The results show that the effect of sequential cutting on the cutting forces is the largest at 90° fiber orientation angle.Oblique cutting experiments were conducted on unidirectional CFRP. The cutting forces and chip morphology between the simulations and the experimental results were compared. The proposed FE model reveals the effect of oblique angle and sequential cutting on the mechanisms of chip formation and surface generation. The results are able to provide guidance in choosing proper cutting parameters and tool geometries to minimize the subsurface damage and potential delamination corresponding to in actual cutting operations of CFRP composites.
Surface texturing is a manufacturing process to generate periodic geometric patterns on component surfaces in order to achieve certain functions, such as tribological property, adhesion, and wettability. This thesis presents a surface texturing technique using ball-end milling with high feed speed and spindle speed modulation. The ratio between the feedrate and the cutting tool radius is in the range of 0.2-0.4 when the spindle speed is a constant, and a certain amount of workpiece material remains after the cutting process to form the surface texture. A sinusoidal modulation signal is added to the spindle speed command, so the spindle speed becomes time-varying in order to generate different texture profiles based on the modulated frequency and amplitude.The cutting tool kinematics of the surface texturing process are modeled considering the tool tip run-out and deflection due to the cutting forces. Z-map method is used to simulate the geometry of the 3-D surface texture based on the tool tip trajectory. The effects of modulation parameters on tool tip trajectories and surface textures are analyzed. The relationship between the micro features of the surface texture and the process parameters are determined. Surface texturing experiments are conducted based on the proposed technique, and tribology tests are performed on the textured surfaces. It is shown that the textured surfaces present frictional anisotropy, which depends on the process conditions and the modulation parameters of the spindle speed. The proposed technique is able to achieve fast generation of various surface textures without additional instrumentation, and the final texture geometry is controllable based on the presented kinematics model.