A comparative study of the effects of milling and abrasive water jet cutting on flexural performance of CFRP

Machining of carbon fibre reinforced polymers is part of the production process that introduces several challenges due to inherent characteristics of CFRPs such as non-homogeneity of their mechanical properties. A comparative analysis of conventional milling and abrasive water jet (AWJ) cutting is performed to quantify the effects of machining induced damage on flexural strength of woven CFRP laminates. The machined surfaces quality is characterized using optical and scanning electron microscopy methods prior to flexural mechanical testing. High-speed Digital Image Correlation technique is also used to measure deformation evolutions and determine fracture mechanisms in relation to the applied machining operation and produced machined surfaces. The effect of machining induced damage on strength of milled samples was less than expected with the AWJ processed samples having the least mechanical properties. The surface morphology analysis revealed that the entry and exit point of the water jet introduced severe surface and subsurface damage across the full thickness. The failure initiation sites were determined by strain distribution maps indicating that machining induced damage promotes failure of the tested CFRPs away from maximum compressive stress observed under the loading points.