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Research Papers

Characterization and Micromilling of Flow Induced Aligned Carbon Nanotube Nanocomposites

[+] Author and Article Information
Mehdi Mahmoodi

e-mail: mahmoom@ucalgary.ca

M. G. Mostofa

e-mail: mgmostof@ucalgary.ca
University of Calgary,
2500 University Drive, NW, Calgary,
Alberta T2N1N4, Canada

Martin Jun

University of Victoria,
3800 Finnerty Road, Victoria V8P5C2,
British Columbia, Canada
e-mail: mbgjun@uvic.ca

Simon S. Park

University of Calgary,
2500 University Drive, NW, Calgary,
Alberta T2N1N4, Canada
e-mail: simon.park@ucalgary.ca

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF Micro AND Nano-Manufacturing. Manuscript received July 23, 2012; final manuscript received December 11, 2012; published online March 22, 2013. Assoc. Editor: J. Rhett Mayor.

J. Micro Nano-Manuf 1(1), 011009 (Mar 22, 2013) (8 pages) Paper No: JMNM-12-1039; doi: 10.1115/1.4023290 History: Received July 23, 2012; Revised December 11, 2012

Carbon nanotube (CNT) based polymeric composites exhibit high strength and thermal conductivity and can be electrically conductive at a low percolation threshold. CNT nanocomposites with polystyrene (PS) thermoplastic matrix were injection-molded and high shear stress in the flow direction enabled partial alignment of the CNTs. The samples with different CNT concentrations were prepared to study the effect of CNT concentration on the cutting behavior of the samples. Characterizations of CNT polymer composites were studied to relate different characteristics of materials such as thermal conductivity and mechanical properties to micromachining. Micro-end milling was performed to understand the material removal behavior of CNT nanocomposites. It was found that CNT alignment and concentrations influenced the cutting forces. The mechanistic micromilling force model was used to predict the cutting forces. The force model has been verified with the experimental milling forces. The machinability of the CNT nanocomposites was better than that of pure polymer due to the improved thermal conductivity and mechanical characteristics.

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Figures

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Fig. 3

TEM image of the 2 wt. % MWCNT/PS composite

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Fig. 4

Volume resistivity of the injection-molded nanocomposites and comparison with compression molded samples

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Fig. 2

Micro-end milling setup

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Fig. 1

(a) Injection molding setup and (b) schematic of the designed mold

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Fig. 5

Thermal conductivity of the injection-molded samples measured in parallel and perpendicular to the flow direction

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Fig. 7

Schematic of the micromilling of CNT nanocomposites

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Fig. 6

Tensile stress–strain curves of the samples under strain rate of 5 mm/min

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Fig. 8

Experimental and simulated tangential (Ft) and radial forces (Fr) of full immersion cutting at feed rate of 4 μm/flute for 2% CNT loading

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Fig. 9

Comparison of experimental and simulated tangential (Ft) and radial forces (Fr) for half immersion at feed rate of 3 μm/flute for 2% CNT loading

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Fig. 10

Root-mean square (RMS) values of resultant forces with respect to the concentration of MWCNT/PS in the in-flow cutting at different feed per tooth (FPT)

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Fig. 11

SEM pictures of the machined slots on (a) plain PS and (b) 5 wt. % MWCNT/PS composites at feed rate of 4 μm/tooth

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Fig. 12

SEM pictures of the chips at a feed rate of 1 μm/flute

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Fig. 13

Comparison of AFM scanned phase images (a) pure PS and (b) 2 wt. % CNT nanocomposite at feed rate of 2 μm/flute

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