CFRP cutting mechanism. (1st report). Surface generation mechanism at very low cutting speeds.

敏明, 金枝; 正行, 高橋

doi:10.2493/jjspe.55.1456

Cited by 17 publications

(9 citation statements)

References 2 publications

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“…As used in this experiment, when the feed rate was smaller than the honing amount, it was considered in the vicinity of cutting edge became a negative rake angle. The result of observing the chip shape, the fiber buckling type [9] of the fine-cutting chips was confirmed. This case considered that shearing of the carbon fiber was difficult or could not be performed.…”

Section: Experimental Results Of the Second Experimentsmentioning

confidence: 58%

“…Figure 9 shows the tool edge without honing (i.e., 10 µm or less), which obviously has a sharp edge. The result of observing the chip shape, a cutting chip with a long shape, such as a fiber cutting type [9] or a delamination type [9] was confirmed. It was considered that ductility mode machining had occurred.…”

Section: Experimental Results Of the Second Experimentsmentioning

confidence: 76%

“…Alternatively, for the case with honing on the tool edge, destruction by compressive load was considered to have occurred near the shear plane because the cutting edge had a negative rake angle. Therefore, cutting chips of fine-dust type, similar to the fiber buckling type [9], were discharged. The case of increased thrust force was considered because accelerated tool wear will induce abrasive wear when fine-cutting chips remain between the tool and the work piece.…”

Section: Experimental Results Of the Second Experimentsmentioning

confidence: 99%

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Effects of Tool-Edge Form during the Drilling of CFRP

Hagino

Inoue

Fujita³

et al. 2017

KEM

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The drilling of carbon fiber reinforced plastics (CFRP) involves many problems such as an extremely short tool life or CFRP delamination occurring at the exit surface of drill. In an effort to solve these problems, this experiment observed the form of the drill’s tool edge. Then, an investigated the form of the tool edge with regard to low-cost, high-precision, and high-efficiency machining processes. The thrust direction of the cutting force is decreased as the CFRP delamination at the exit surface of drill is decreased. It is considered suppressing the delamination on the exit surface of drill by reducing the thrust force during drilling. In this experiment, the CFRP materials had a thickness of 4 mm. This experiment used sintered carbide, straight shank drill tooling with a diameter of 6 mm. Ten different types of straight shank drills with different point angles and coating treatment were tested. Additionally, this experiment an evaluated the cutting force, the cutting temperature, and the CFRP delamination at the exit surface of drill through the drilling and processing of 100 holes. Moreover, this experiment an evaluated the effects of chamfering of honing the tool edge with regard to the drilling and machinability of CFRP. This experiment used CFRP material with a thickness of 8 mm and four types of sintered carbide drills. As a result, the CFRP delamination distance of the exit surface of drill became smaller at point angles 130° and 140°. No differences in the cutting force or the cutting temperature were observed due to the different point angles. The results of the evaluation indicated that for the case without honing, the thrust force becomes 1/3 less than that for the case with honing of the drill tool. Additionally, in the case of without honing, CFRP delamination was suppressed at the exit surface of drill.

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Section: Experimental Results Of the Second Experimentsmentioning

confidence: 58%

Section: Experimental Results Of the Second Experimentsmentioning

confidence: 76%

Section: Experimental Results Of the Second Experimentsmentioning

confidence: 99%

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Effects of Tool-Edge Form during the Drilling of CFRP

Hagino

Inoue

Fujita³

et al. 2017

KEM

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“…The material removal mechanism of milling in different fiber directions is diverse because of the anisotropy of fiber composites. Koplev et al [32] conducted an experimental comparison of cutting unidirectional carbon fiber-reinforced plastic (UD-CFRP) perpendicular and parallel to the fiber direction using a fast stop device. Poor surface quality and serious sub surface tear are produced when cutting perpendicular to the fiber direction.…”

Section: Materials Removal Mechanismmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

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Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

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“…For this reason, it is inferred that the tool wear increases because the cutting tool discharges the carbon fiber chips as shown in Fig. 8(a), which increases the cutting forces [12], and/or because after the carbon fibers cause elastic deformation, the carbon fibers rub the flank face of the cutting tool at the time of recovery.…”

Section: Relationship Between Cutting Methods and Tool Wearmentioning

confidence: 99%

Tool Wear Reduction Effect of Water-Miscible Cutting Fluid in End Milling of Carbon Fiber Reinforced Plastic

Matsuoka¹

2017

IOSR JEN

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-Recently, carbon fiber reinforced plastic (CFRP) has come to be commonly used in the aviation and automobile industries. However, it is well known that CFRP is a difficult-to-cut material because it increases tool wear dramatically. This paper presents the influence of water-miscible cutting fluid on tool wear (tool life) in the end milling of CFRP. The conclusions can be summarized as follows: In down-cut milling, the tool wear is less than that in up-cut milling. The tool wear obtained with a feed rate of 100 mm/min is less than that obtained with 200 mm/min. The water-miscible cutting fluid used in the experiments reduces tool wear and improves tool life compared with the cases using dry cutting and water, irrespective of the cutting speeds. The velocity dependence is low; that is, the tool life obtained when changing the cutting speed from 69 m/min to 171 m/min is almost unchanged. The tool life curve obtained with the water-miscible cutting fluid tends to show a shortened tool life as the cutting speed is decreased, which is opposite of the tool life trend for dry cutting. The average wear rate in the initial wear region in addition to the low initial wear width affect the tool life; that is, when the wear rate is low, the tool life tends to extend.

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CFRP cutting mechanism. (1st report). Surface generation mechanism at very low cutting speeds.

Cited by 17 publications

References 2 publications

Effects of Tool-Edge Form during the Drilling of CFRP

Effects of Tool-Edge Form during the Drilling of CFRP

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Tool Wear Reduction Effect of Water-Miscible Cutting Fluid in End Milling of Carbon Fiber Reinforced Plastic

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