Accounting for the peculiarities of abrasive machining of carbon-carbon materials and tools for its implementation

Authors

DOI:

https://doi.org/10.20535/2521-1943.2026.10.2(109).352206

Keywords:

carbon-carbon composite, abrasive processing, diamond-abrasive elastic tool, cutting simulation

Abstract

Problem: Processing carbon-carbon (C/C) composites is accompanied by significant difficulties due to their quasi-brittle fracture mechanics and the tendency of fine carbon dust to clog the cutting zone when using diamond cutting tools. Existing continuous models treat the elastic cutting tool as a vibrating string, which does not allow for the microdynamic interactions between grains and bonds that are critical for understanding the mechanisms of sludge removal and process stability.

Objective: The main objective is to develop a comprehensive 8-degree-of-freedom coupled model with concentrated parameters for modeling the stochastic dynamics of abrasive processing and investigating the hypothesis of grain rotational motion as a mechanism for improved slurry removal.

Methodology: The work models a localized segment of a rope with four active abrasive grains as a discrete system with 8 degrees of freedom. The grains are considered as rigid bodies with translational and rotational compliance, connected by a steel core and fixed in a viscoelastic nickel bond. The dynamics of the system are described by coupled differential equations using the Reissner-Sagotsi rotational stiffness and Rayleigh damping formulas. The cutting process is simulated as a stochastic sequence of pulses reflecting the heterogeneity of the material.

Results: A mathematical modeling method was proposed that can investigate the rotational and translational movements of grain during cutting, which will allow finding the parameters of the cutting tool that will facilitate the removal of chips from the cutting zone.

Conclusions: The proposed model is a theoretical tool for finding the parameters of diamond cutting tools, in particular the viscoelastic properties of the matrix, to achieve a balance between material removal rate and dynamic stability.

References

  1. Z. Tolde, V. Starý, and T. Kubart, "Tribological properties of carbon-carbon composite and of a surface layer of pyrolytic carbon" Ceramics – Silikáty, vol. 52, no. 1, pp. 37–44, 2008.
  2. P. V. Te, "Diamond wire sawing for PV: Short- and long-term challenges," Photovoltaics International, vol. 12, pp. 1–5, 2011.
  3. University of Michigan, "MTM diamond wire saw," WUMRC, Aug. 2013
  4. Jiang, S., Tang, C., Li, X. et al. Discrete element modeling of the machining processes of brittle materials: recent development and future prospective. Int J Adv Manuf Technol 109, 2795–2829 (2020). doi: 10.1007/s00170-020-05792-y
  5. D. K. Aspinwall, et al., "The effect of the elastic modulus of the bond between the wheel and the impact tool on the stresses in the SHM," Machines, vol. 10, no. 7, p. 543, 2022. doi: 10.3390/machines10070543
  6. J. W. Pearce, "Assessment of vitrified CBN wheels for precision grinding," Ph.D. dissertation, Liverpool John Moores University, 1999, p. 54.
  7. Khoshouei Esfahani, Mehrbod & Jalalian, Mohammad Hossein & Bagherpour, Raheb. (2020). THE EFFECT OF GEOLOGICAL PROPERTIES OF DIMENSION STONES ON THE PREDICTION OF SPECIFIC ENERGY (SE) DURING DIAMOND WIRE CUTTING OPERATIONS. Rudarsko-geološko-naftni zbornik. 35. 17-27. doi: 10.17794/rgn.2020.3.2.
  8. Zhang C, Dong Z, Zhao Y, Liu Z, Wu S, Yang J. Sawing Force Prediction Model and Experimental Study on Vibration-Assisted Diamond Wire Sawing. Micromachines (Basel). 2022 Nov 19;13(11):2026. doi: 10.3390/mi13112026
  9. Chung, Chunhui & Kao, Imin. (2011). Modeling of axially moving wire with damping: Eigenfunctions, orthogonality and applications in slurry wiresaws. Journal of Sound and Vibration - J SOUND VIB. 330. 2947-2963. doi: 10.1016/j.jsv.2011.01.008.
  10. A. Salenko, O. Chencheva, V. Glukhova, V. Shchetynin, M. R. F. Budar, S. Klimenko, and E. Lashko, “Effect of slime and dust emission on micro-cutting when processing carbon-carbon composites,” Eastern-European Journal of Enterprise Technologies, vol. 3, no. 1(105), pp. 38–51, 2020, doi:10.15587/1729-4061.2020.203279.
  11. O. Salenko, O. Chencheva, V. Shchetynin, V. Gluchova, E. Lashko, and M. R. Budar, “Cutting carbon-carbon composites by the diamond drills variable cyclic feed,” Mechanics and Advanced Technologies, no. 3(87), pp. 47–60, Dec. 2019, doi:10.20535/2521-1943.2019.87.188721.

Published

2026-06-18

How to Cite

[1]
M. Molnar and O. Salenko, “Accounting for the peculiarities of abrasive machining of carbon-carbon materials and tools for its implementation”, Mech. Adv. Technol., vol. 10, no. 2(109), Jun. 2026.

Issue

Vol. 10 No. 2(109) (2026): in progress

Section

Advanced Mechanical Engineering and Manufacturing Technologies

License

Copyright (c) 2026 Михайло Молнар, Олександр Саленко

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

The ownership of copyright remains with the Authors.
 
Authors may use their own material in other publications provided that the Journal is acknowledged as the original place of publication and National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” as the Publisher.

Authors who publish with this journal agree to the following terms:

  1. Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under CC BY 4.0 that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.

  2. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.

  3. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work