Online monitoring of pre-crack initiation in carbon fiber-reinforced thermoplastic composites by an ultrasonic cutting tool using high-speed optical imaging and infrared thermography.

The ultrasonic-assisted manufacturing process is a promising machining approach for composite materials as it exerts less force, making it ideal for the aerospace and automotive sectors. This work reports about the pre-crack initiation in carbon fiber reinforced (CF)/ poly-ether-ether-ketone (PEEK) composite under ultrasonic frequency at room temperature. An iron-based cutting tool matching the system's resonance frequency (20 kHz) was used to perform the ultrasonic pre-cracking.