Helical milling for making holes on carbon fiber-reinforced polymer

Su, Chunjie; Cheng, Xiang; Yan, Xinhua; Zheng, Guangming; Li, Yang; Zhang, Mu

doi:10.1007/s00170-022-09749-1

Cited by 14 publications

(4 citation statements)

References 30 publications

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“…Sun et al [17] concluded that the cutting temperature produced by helical milling is lower than that of traditional drilling. Scholars found that axial feed is the most critical factor for generating thrust and the addition of bers has a signi cant impact on the cutting force [18][19]. It can be seen that compared with drilling, helical milling has obvious advantages in reducing the cutting temperature, reducing the cutting force and increasing the smooth chip removal, and reducing the damage of the entrance and exit [20][21].…”

Section: Introductionmentioning

confidence: 99%

Study on removal mechanism and surface quality in helical grinding 2.5D-Cf/SiC composites

Zhou,

Chen,

Liu

et al. 2024

Preprint

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Carbon fiber reinforced ceramic matrix composites have excellent heat resistance and wear resistance, making them extensively utilized in the aviation and aerospace industries. However, processing carbon ceramics is challenging due to the inherent difficulty. Traditional hole-making methods often result in issues such as delamination and tearing during the processing of carbon ceramics. Helical grinding has emerged as a novel processing technology that shows promise for difficult materials like carbon ceramics. To address the lack of clarity regarding the removal mechanism and formation mechanism of material damage during helical grinding of carbon ceramic materials. Firstly, this study models the trajectory and maximum undeformed chip thickness for single abrasive. Subsequently, analyzes the influence of fiber anisotropy on the removal mechanism during helical grinding of carbon ceramics. The study also investigates the mechanisms behind exit damage occurring during carbon ceramic helical grinding processes. Finally, examines helical grinding technological parameters affect surface quality by analyzing their impact on undeformed chip thickness. The results indicate that matrix occurs brittle fracture during helical grinding. Four typical removal mechanism emerge for different fiber angles: debonding is predominant at 0°; fiber fracture occurs at 45°; fiber shear occurred at 90°; fiber pull out occurred at 135°. Hole exit damage is influenced by fiber direction with minimal damage observed when shear fracture occurs at angles 45° and 90° while burrs phenomenon and tear phenomenon are prevalent at angles 0°and 135° respectively. By increasing orbital rotation speed and spindle speed or decreasing feed pitch, surface quality improved. Grinding parameters significantly affect surface quality through changing undeformed chip thickness and surface residual height.

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Section: Introductionmentioning

confidence: 99%

Study on removal mechanism and surface quality in helical grinding 2.5D-Cf/SiC composites

Zhou,

Chen,

Liu

et al. 2024

Preprint

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show abstract

“…Carbon fiber reinforced polymer (CFRP) has the characteristics of low specific gravity, high strength, and high temperature resistance, and has been widely used in aerospace and other fields [1][2][3]. However, CFRP has the characteristics of anisotropy and high brittleness, which makes it prone to defects such as burrs and tearing during processing [4,5]. Therefore, the hole quality of CFRP has become a key factor affecting the processing quality and performance of structural parts.…”

Section: Introductionmentioning

confidence: 99%

Comparative study on cutting performance of CFRP with flat end milling cutter and circular arc milling cutter in inclined angle milling

Liu,

Chen,

et al. 2024

Preprint

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Carbon fiber reinforced polymer (CFRP) has excellent mechanical properties and has been widely used in aviation, aerospace, and other fields. Due to the anisotropy of CFRP, it is easy to cause cutter wear during the machining process, resulting in machining defects such as burrs, tearing and delamination. In this paper, a comparative experimental study on the inclined angle milling of CFRP with flat end milling cutter and circular arc milling cutter is carried out. The axial force, cutter wear, the quality of hole entrance and exit and the hole wall micro-morphology of the two cutters under the inclined angle milling method were analyzed. The results show that compared with the tip area of flat end milling cutter, the arc transition area of circular arc milling cutter increases the contact area with the workpiece and reduces the milling axial force. The cutter wear of circular arc milling cutter is mainly concentrated in the arc transition area, and the wear gradually diffuses to the nearby cutting edge. However, the wear of flat end mill cutter is mainly concentrated in the cutter tip area. As the number of holes increases, the cutter tip gradually becomes blunt, and the wear area further expands to the area near the cutter tip. With the increase of cutter wear, the entrance defects of the processing hole of the two cutters are less, the exit of the hole of the circular arc milling cutter has defects such as tearing and burrs. In addition, there are defects such as fiber exposed and cavities on the surface of the hole wall. Compared with the circular arc milling cutter, the flat end milling cutter has more defects at the exit of the hole. At the same time, many surface cavities, pits, and fiber pull-out phenomena on the surface of the hole wall.

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“…Helical milling is a feasible milling method for the large-diameter holes in hard materials [4,5] . The key cutting parameters such as spindle speed, feed speed, and pitch on cutting force are investigated and optimized for helical milling by Su et al [6] . Milling holes of materials with poor cutting performance requires high cutting force, which easily leads to high cutting temperature and serious tool wear.…”

Section: Introductionmentioning

confidence: 99%

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Han,

Gu,

et al. 2023

Int J Adv Manuf Technol

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The machining time is mainly related to the tool path and the corresponding feed speed, while the trochoidal tool path depends on the trochoidal step and trochoidal radius. The material removal rate is periodically distributed along the tool path in trochoidal milling a hole. But more than half of tool paths do not cut material in trochoidal milling a hole, so a constant feed speed in milling a hole will limit the machining efficiency. In this paper, a trochoidal radius optimization approach is presented to improve the efficiency of trochoidal milling a hole, which considering the optimal feed speed. Firstly, the mathematical representation of the trochoidal radius is formulated by analyzing the generation principle of trochoidal path, so the trochoidal radius could be determined under the premise of the hole diameter, maximum uncut radial material and the tool diameter are fixed. Furthermore, the trochoidal radius optimization model， which based on the adjusted feed speed, is established with the goal of minimizing the machining time. Secondly, an adaptive feed speed scheduling strategy for trochoidal milling is proposed, which is constrained by stable material removal rate and adjusted by a cubic polynomial algorithm. Finally, taking a hole machining as an example, simulation and experimental results show that the efficiency of applying the trochoid milling method proposed has increased by 13.8% compared to traditional helix milling method.

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Helical milling for making holes on carbon fiber-reinforced polymer

Cited by 14 publications

References 30 publications

Study on removal mechanism and surface quality in helical grinding 2.5D-Cf/SiC composites

Study on removal mechanism and surface quality in helical grinding 2.5D-Cf/SiC composites

Comparative study on cutting performance of CFRP with flat end milling cutter and circular arc milling cutter in inclined angle milling

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

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