Experimental Study on Milling CFRP with Staggered PCD Cutter

Chen, Tao; Wang, Daoyuan; Gao, Fei; Liu, Xianli

doi:10.3390/app7090934

Cited by 9 publications

(5 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Composite materials with a matrix based on resin or polymer belong to a group of materials with specific properties, the use of which is constantly increasing along with the requirements for tools [1]. The mutual combination of matrix and reinforcing fibers can achieve different mechanical properties, which must be considered when choosing a cutting tool [2,3].…”

Section: Introductionmentioning

confidence: 99%

Wear Study of Coated Mills during Circumferential Milling of Carbon Fiber-Reinforced Composites and Their Influence on the Sustainable Quality of the Machined Surface

2022

View full text Add to dashboard Cite

Composite materials made of fiber-reinforced plastic laminates are highly susceptible to surface damage caused by wear during contour milling, especially with inappropriate tool and cutting material properties. Improper choice of tools and cutting conditions lead to delamination between applied layers, thermal damage of materials in the polymer matrix, and reduction of the edge quality of cutting tools. The study was devoted to circumferential milling of twill-bonded CFRP (carbon-fiber-reinforced polymer) sheets with a focus on cutting forces and tool flank face wear, including their effect on the machined surface structure, roughness, and topography of the laminate. The main objective of the study is to investigate the feasibility of applying conventional coated tools, which are not primarily designed for milling CFRP, in comparison to a dedicated DLC (diamond-like carbon) coated tool, due to economic and distribution availability and the possibility of providing suitable cutting conditions during milling. The study provides results confirming the possibility of using conventional tools for machining CFRP and provides relevant experimental results that can be implemented for optimal tool selection, tool life criteria, cutting conditions, and machining strategies including low energy consumption. The best values of the investigated parameters were obtained when using the ECSSF (instrument designation) tool with DLC coating.

show abstract

Section: Introductionmentioning

confidence: 99%

Wear Study of Coated Mills during Circumferential Milling of Carbon Fiber-Reinforced Composites and Their Influence on the Sustainable Quality of the Machined Surface

2022

View full text Add to dashboard Cite

show abstract

“…In the milling of CFRP with PCD cutters, the primary wear mechanism of the cutter is abrasive wear. 15 This abrasive wear is affected by the wear process of the PCD tool where the cobalt binder phase of the PCD cutter is first removed in cutting CFRP, and then the diamond grains cleave easily under the friction and mechanical impacts from fibers. 27 The force between the cutter and fibers affects the material removal rate of the cutter, which means that a higher cutting force causes more severe tool wear.…”

Section: Tool Wear Analysismentioning

confidence: 99%

“…In terms of tool material and geometry, the wear rate of the diamond-coated cutter was lower than that of the TiB2-coated cutter, 13 and the polycrystalline diamond (PCD) milling cutter had the highest tool life compared to highspeed steel and TiAlN-coated tungsten carbide milling cutter. [14][15][16] In addition, the machining parameter is another critical factor that affects tool wear and machining quality. [17][18][19] Ozkan et al 20 investigated the effect of machining parameters on tool wear with uncoated carbide inserts under various cutting speeds and feed rates.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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

Wang

Chen

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

Milling carbon fiber reinforced polymer (CFRP) composites faces significant challenges, such as rapid tool wear leading to machining damage, even for a polycrystalline diamond (PCD) cutter. However, the effects of the milling conditions on the tool wear of PCD cutters remain unclear. This study investigated the effects of the cutting speed and fiber orientation on the tool wear of a PCD cutter and the corresponding machining quality in milling CFRP. These effects were analyzed by considering fiber and cutter interactions, and milling experiments with a PCD cutter were conducted for validation based on the analyses of cutting-edge profiles, cutting forces, burr area, and machined surface of CFRP. The worn cutting edge profiles were found to be elliptical in shape for cutting CFRP in different fiber orientations owing to the more severe wear on the flank face and cutting edge. Tool wear decreased with increasing cutting speed under a consistent feed per tooth, which further led to a reduction in the cutting force, burr area, and surface roughness. In addition, the maximum and minimum variations of worn cutting edge profiles were found in the cutting of 45° and 135° CFRP, respectively, suggesting that frequently changing the tool working position at 45° could suppress burr damage and increase tool life.

show abstract

“…Finally, milling is considered as a finishing operation to obtain high-quality surfaces in complex shapes. However, delamination and burrs with uncut fibres are often observed due to the complex interaction between the cutting tool and the laminate [13][14][15]. These resultant machining defects could lead to the nucleation of cracks in the surface with a drastic reduction in the fatigue life of the components [16].…”

Section: Introductionmentioning

confidence: 99%

A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates

et al. 2021

View full text Add to dashboard Cite

Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45∘ and 90∘ manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation.

show abstract

Experimental Study on Milling CFRP with Staggered PCD Cutter

Cited by 9 publications

References 21 publications

Wear Study of Coated Mills during Circumferential Milling of Carbon Fiber-Reinforced Composites and Their Influence on the Sustainable Quality of the Machined Surface

Wear Study of Coated Mills during Circumferential Milling of Carbon Fiber-Reinforced Composites and Their Influence on the Sustainable Quality of the Machined Surface

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

A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates

Contact Info

Product

Resources

About