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This paper presents a novel concept for extending the life of the tools that are used in the milling process of carbon-fiber-reinforced plastic (CFRP) composites. Three types of tools were compared in milling tests; tool I: an uncoated tungsten carbide (WC-Co) tool, tool II: a polycrystalline diamond (PCD) tool, and tool III: a combination tool comprising a PCD layer surface with a thickness of 100 μm and a WC-Co substrate flank surface. The measurement of changes in cutting forces over cutting distance revealed that tool III had a better (tool) life performance than the other tools. Additionally, observation of changes in the edge profiles of the tools revealed that the effective edge sharpness of tool III remains constant during the milling tests. The difference between the wear rates of the PCD rake and WC-Co flank surfaces in tool III maintained a constant effective sharpness during the milling process, and it extended the tool life. Based on our findings, we concluded that using the difference between the wear rates of rake and flank surfaces is an effective technique for tool life extension in the milling process of CFRP laminates.

This paper discusses tool-wear processes in the milling of carbon fiber-reinforced plastic (CFRP) laminates. Plane down-milling tests with unidirectional and cross-directional CFRP laminates were performed using two types of cutting tools made of tungsten carbide and polycrystalline diamond. Measurements of the changes in the cutting forces and tool-wear widths over the cutting distance revealed that the fiber orientation direction in the CFRP laminates relative to the tool-traveling direction is an important parameter to determine the tool-wear processes. Additionally, based on obtained experimental results, a wear parameter to characterize cutting tool wear is introduced. This parameter can accurately explain the relationship between the worn tool-edge profiles and the processed-surface quality.

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