Effect of Machining Settings and Tool Geometry on Surface Quality After Machining of Al/CFRP Sandwich Structures

Abstract

The paper describes the effect of cutting parameters and tool geometry on the surface quality after machining of an Al/ CFRP (aluminium alloy/ Carbon Fibre Reinforced Plastics) sandwich structure. A two-layer sandwich structure made of an EN AW 2024 aluminium alloy and Carbon Fibre Reinforced Plastics (CFRP) was examined. The experiment used the process of peripheral milling. The experiment investigated the effects of cutting speed (v c ), feed per blade (f z ) and helix angle (λ s ) on surface quality as defined by differences in the height of materials. It was also analysed how the machining conditions described above affected the values of cutting force components. In the experimental stage of the study, uncoated, double-bit carbide mill cutters with working diameter D c = 12 mm and a variable helix angle (λ s = 20°, λ s = 35°, λ s = 45°) were used. The results have shown that cutting parameters and tool geometry do affect the surface quality and cutting forces after milling of the sandwich structure. The lowest material height difference was achieved when machining with the helix angle λ s = 45°, cutting speed v c = 300 m/min and feed per blade f z = 0.08 mm/blade. The highest material height difference occurred after machining under the following conditions: v c = 300 m/min, f z = 0.08 mm/min, λ s = 20°. The minimum cutting force value was obtained for cutting parameters: v c = 80 m/min, f z = 0.08 mm/blade during milling with the helix angle λ s = 45°. The maximum cutting force was recorded during machining with the helix angle λ s = 20˚, cutting speed v c = 400 m/min and feed per blade f z = 0.08 mm/blade.

Evaluation of Machinability Indicators in Milling of Thin-Walled Composite Structures

“…Carbide insert cutters are relatively cheap compared to diamond insert cutters or diamond cutters. In milling processes for carbon fiber-reinforced plastics (CFRPs) and glass fiber-reinforced plastics (GRFPs), the tool selection depends on the material of the blade, whereas in the milling of aramid fiber-reinforced plastics (AFRPs), the geometry of the blade is of decisive importance [10]. In addition to that, the choice of a tool for a given machining process depends on the number of operations and, primarily, on the type of the workpiece itself.…”

Analysis of Geometric Surface Structure and Surface Layer Microhardness of Ti6Al4V Titanium Alloy after Vibratory Shot Peening

“…The need to reduce the weight of aircraft components involves the use of thin-walled components. To ensure the required accuracy and surface roughness of such elements, the use of appropriate machining conditions must be applied [14][15][16]. Due to a series of dynamic phenomena occurring in the process, as the thickness of the machined elements decreases, there is an increase in the roughness of the machined surface.…”

Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry

“…The selection of parameters in the milling of polymer composites depends on the material structure, fiber orientation, fiber type and their share in the material [ 52 ]. In most cases, cutting speeds of 20 ÷ 250 m/min [ 46 , 53 , 54 , 55 , 56 ] and even 500 m/min [ 57 ] are used for milling carbon fiber-reinforced plastics (CFRPs).…”