Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Abstract

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.

Influences of Main Machining Process Parameters and Tool Wear on The Machining Damage Generated During Edge Milling CFRP Composites

“…Moreover, feed rate has more impact on tool wear than that of cutting speed. This result is consistent with those documented by [26]. However, in the study of [27], the authors showed that cutting speed has a stronger impact on tool wear compared with those feed rates because cutting speed is the major factor influencing cutting temperatures.…”

Effects of cutting speed and fiber orientation on tool wear and machining quality in milling CFRP with PCD cutter

“…They found that surface roughness (Ra) increased with increasing feed rate and decreased with increasing cutting speed. In contrast, different results were found by Elgnemi et al 23 in which the cutting force and tool wear increased as the cutting speed increased from 100 m/min to 200 m/min during the dry milling of CFRP with carbide milling cutters. Nor Khairusshima et al 24 studied the tool wear of a carbide milling cutter and found that the tool wear rate increased with increasing cutting speed and feed rate.…”

The Effect of Clearance Angle on Tool Life, Cutting Forces, Surface Roughness, and Delamination during Carbon-Fiber-Reinforced Plastic Milling

“…In CFRP, the fibers bear the load while the resin facilitates force transfer between the fibers. Therefore, the failure modes of the material can be analyzed primarily based on the stresses experienced by the fibers [ 10 , 11 ].…”