Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions

Abstract

The application of Carbon Fiber Reinforced ThermoPlastic matrix composites (CFRTP) is constantly increasing in various industrial sectors. Their mechanical properties and advantages compared to thermoset composite materials make them very important materials. Nevertheless, CFRTP machining generates a current problem due to the anisotropy of these materials, the di culty of impregnation of the reinforcement in the matrix and its low melting temperature. For this reason, the study of conventional operations such as milling to achieve geometries with a good surface quality and reduced cosmetic defects is a line of research of great interest. In this article, a comparison of ve cutting tools with different geometries has been made in CFRTP milling. The surface quality and the formation of visual defects such as ber pull-out have been evaluated for each tool and combination of cutting parameters. In this sense, 16.42 µm in terms of Rz is the minimum average value for the complete experiment obtained for a conventional tool (Tool A). However, surface qualities in terms of Rz close to 20 µm and minimum cosmetic defects have been obtained with a hybrid tool (Tool C) with -10° helix angle and 8 teeth with a combination of cutting parameters of 0.07 mm/tooth and 3000 rpm, being the most complete tool of the experiment.

Temperature field evolution and thermal-mechanical interaction induced damage in drilling of thermoplastic CF/PEKK – A comparative study with thermoset CF/epoxy

“…As shown by Fig. in drilling of thermoplastic CF/PEEK [28], CF/pCBT [42] and CF/ABS [30,43], milling of CF/polyurethane [44] and orthogonal cutting of CF/PEEK [45]. Compared to CF/PEKK, the CF/epoxy chips are less intact and contain micro-cracks.…”

A Novel Method for Damage Prediction in BCF/PEEK Drilling Using an Innovative Drill Tool

“…Substantial drilling and holemaking operations are involved in the riveting and bolting processes, and the tensile strength and fatigue damage of structural components are signi cantly in uenced by high-quality hole-making [8]. The drilling of CFRTP using conventional cutting tools is susceptible to processing damage such as tearing, burrs, and delamination at hole exits [9]- [11], thereby compromising the reliability of the product. The traditional twist drill exhibits a relatively long transverse cutting edge, and during the drilling process of composites, approximately 60% of the total thrust force is generated by the transverse edge, thereby leading to the occurrence of delamination at hole exits [12].…”

Investigating the material removal mechanism and cutting performance in ultrasonic vibration-assisted milling of carbon fibre reinforced thermoplastic

“…The main difference between CFRTP and CFRP is the variation in matrix performance, leading to notable differences in research on machining methods [12]. In investigating CF/thermoplastic polyurethane (CF/TPU), Sambruno et al [13] conducted milling experiments employing five different milling tools to evaluate the influences of tool geometry and cutting conditions on surface defects and roughness. The findings revealed that the best surface quality was achieved when using the milling tool with a 10°helix angle and 8 teeth under the milling parameter combination of 0.07 mm/tooth and 3000 rpm.…”