Methods of cutting fiber reinforced polymer composite workpieces with a pure waterjet
First Claim
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1. A method of trimming a fiber reinforced polymer composite workpiece, the method comprising:
- providing the fiber reinforced polymer composite workpiece in a post-molded or post cured, untrimmed state in which fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece extends beyond a final component profile thereof; and
thereaftergenerating a pure waterjet via a cutting head in liquid phase unladened with solid particles at an operating pressure of at least 60,000 psi;
directing the pure waterjet to pass through the fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece in the post-molded or post cured, untrimmed state; and
moving at least one of the cutting head and the fiber reinforced polymer composite workpiece relative to the other at a cutting speed along a predetermined path while maintaining the operating pressure of at least 60,000 psi such that the pure waterjet trims the fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece to the final component profile wherein the cutting speed is selected to produce an edge of the fiber reinforced polymer composite workpiece with a predetermined surface roughness having at least one of an Ra value of about 22 ±
5 microns and an Rz value of 128 ±
20 microns.
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Abstract
Methods of trimming fiber reinforced polymer composite workpieces are provided which use a pure waterjet discharged from a cutting head in liquid phase unladened with solid particles at an operating pressure of at least 60,000 psi and in combination with other cutting parameters to provide a final component profile without delamination, splintering, fraying or unacceptable fiber pullout or fiber fracture.
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Citations
24 Claims
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1. A method of trimming a fiber reinforced polymer composite workpiece, the method comprising:
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providing the fiber reinforced polymer composite workpiece in a post-molded or post cured, untrimmed state in which fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece extends beyond a final component profile thereof; and
thereaftergenerating a pure waterjet via a cutting head in liquid phase unladened with solid particles at an operating pressure of at least 60,000 psi; directing the pure waterjet to pass through the fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece in the post-molded or post cured, untrimmed state; and moving at least one of the cutting head and the fiber reinforced polymer composite workpiece relative to the other at a cutting speed along a predetermined path while maintaining the operating pressure of at least 60,000 psi such that the pure waterjet trims the fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece to the final component profile wherein the cutting speed is selected to produce an edge of the fiber reinforced polymer composite workpiece with a predetermined surface roughness having at least one of an Ra value of about 22 ±
5 microns and an Rz value of 128 ±
20 microns. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A method of trimming a fiber reinforced polymer composite workpiece, the method comprising:
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providing the fiber reinforced polymer composite workpiece in a post-molded or post cured, untrimmed state in which fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece extends beyond a final component profile thereof, the fiber reinforced polymer composite workpiece having a thin shell structure; and
thereaftergenerating a pure waterjet via a cutting head in liquid phase unladened with solid particles at an operating pressure of at least 60,000 psi, the cutting head supported by a multi-axis manipulator; and moving the cutting head via the multi-axis manipulator relative to the fiber reinforced polymer composite workpiece along a predetermined path while directing the pure waterjet to pass through the fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece, maintaining the operating pressure of at least 60,000 psi, and controlling a cutting speed based on a plurality of operating parameters including material thickness, material type, operating pressure, standoff distance and orifice size, such that the pure waterjet trims the fiber reinforced polymer composite material of the fiber reinforced polymer composite workpiece to the final component profile thereby defining an edge of the fiber reinforced polymer composite workpiece with a surface roughness having at least one of an Ravalue of about 22 ±
5 microns and an Rz value of 128 ±
20 microns.
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Specification