ERI: Mitigating Challenges in Machining Additively Manufactured Carbon Fiber Reinforced Polymer Composites through Mechanics and Tribology

Understanding the machining behavior of additively manufactured carbon fiber reinforced polymer (CFRP) composites is critical for advancing their application in aerospace, automotive, and defense industries. While CFRP composites are widely valued for their high strength-to-weight ratio and thermal stability, their heterogeneous structure and anisotropic properties make machining a persistent challenge. Additive manufacturing of CFRP composites introduces additional complexity due to layer-by-layer deposition, variations in fiber orientation, and differences in in-fill structures. This Engineering Research Initiation (ERI) project aims to establish a fundamental understanding of how additive manufacturing affects the machinability of CFRP composites and to develop innovative cooling-lubrication strategies that mitigate these challenges. Insights gained from this work will enhance the integration of additive and subtractive manufacturing for CFRP components, contributing to the advancement of lightweight, high-performance materials for national defense, transportation, and industrial applications. The project also supports workforce development by training undergraduate and graduate students in experimental methods, modeling, and simulation tools in advanced manufacturing. The research will investigate the mechanics and tribology of tool–workpiece interactions during machining of additively manufactured CFRP composites, focusing on the influence of fiber orientation, layer structure, and in-fill patterns on material removal and damage mechanisms. Experimental studies will include in-situ imaging, machining tests, and pin-on-disc tribology experiments, complemented by numerical modeling to predict stress, temperature, and material response during cutting. The project will explore sustainable cooling-lubrication strategies, including minimum quantity lubrication and cryogenic cooling, to reduce thermal and mechanical damage while improving surface finish and tool life. By establishing a mechanistic understanding of machining phenomena and identifying effective mitigation strategies, this project will enable more reliable and efficient post-processing of additively manufactured CFRP composites. The resulting insights will facilitate broader adoption of additive manufacturing in critical high-performance components, advancing lightweighting, sustainability, and technological competitiveness in U.S. manufacturing. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria. NSF Award ID: 2552344 | Program: 01002627DB NSF RESEARCH & RELATED ACTIVIT | Principal Investigator: Muhammad Jahan | Institution: Miami University, OXFORD, OH | Award Amount: $200,000 View on NSF Award Search: https://www.nsf.gov/awardsearch/show-award/?AWD_ID=2552344 View on Research.gov: https://www.research.gov/awardapi-service/v1/awards/2552344.html