Research on Tool Wear and Surface Integrity of CFRPs with Mild Milling Parameters
Source abstract
Abstract
Carbon fiber-reinforced polymer composites are widely used in aviation and aerospace applications due to their excellent mechanical properties. Numerous studies have focused on tool wear at extreme machining parameters (f ≥ 540 mm/min) to accelerate tool wear experiments. However, using mild machining parameters is also instructive for current process production. To investigate the effect of wear on the surface integrity of CFRPs under mild parameters, a tool wear experiment on CFRPs was carried out at a conventional feed rate (f = 60 mm/min). The results show a cutting temperature increase of 47%, a cutting force increase of 53% and a flank wear width increase of 282% for PCD tools (with mild milling parameters) from 0 to 100 m of cutting length. As the cutting temperature reaches the glass transition temperature, Tg, during the stable wear stage, severe burrs and a large number of cavities appeared on the groove, and the subsurface with granular wear on flank wear land due to the transform of the matrix. Furthermore, Ra and Rz exhibit good indicators of cutting length and subsurface damage.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced machining processes and optimization · Tribology and Wear Analysis · Advanced Surface Polishing Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
School of Intelligent Manufacturing, Taizhou University, Taizhou 318000, China
Institute of WenLing Research, Taizhou University, Taizhou 317500, China
Funding
Natural Science Foundation of Zhejiang Province, China
References (39)
Show source-provided references
1. Numerical model of unidirectional CFRP in machining: Development of an amended friction model10.1016/j.compstruct.2020.113075 ↗
2. Cutting force modeling of machining carbon fiber reinforced polymer (CFRP) composites: A review10.1016/j.compstruct.2022.116096 ↗
3. Numerical prediction of the chip formation and damage response in CFRP cutting with a novel strain rate based material model10.1016/j.compstruct.2022.115746 ↗
4. Numerical study of interface damage formation mechanisms in machining CFRP/Ti6Al4V stacks under different cutting sequence strategies10.1016/j.compstruct.2022.115236 ↗
5. Surface roughness prediction model in high-speed dry milling CFRP considering carbon fiber distribution10.1016/j.compositesb.2022.110230 ↗
6. Damage pattern recognition and damage evolution analysis of unidirectional CFRP tendons under tensile loading using acoustic emission technology10.1016/j.compstruct.2020.111948 ↗
7. Xu, Z., and Wang, Y. (2022). Study on Milling Force and Surface Quality during Slot Milling of Plain-Woven CFRP with PCD Tools. Materials, 15.10.21203/rs.3.rs-1369897/v1 ↗
8. A semi-analytical model for predicting tool wear progression in drilling CFRP10.1016/j.wear.2021.204119 ↗
9. Ciecieląg, K., and Zaleski, K. (2022). Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry. Materials, 15.10.3390/ma15175949 ↗
10. Szymański, M., Przestacki, D., and Szymański, P. (2022). Tool Wear and Surface Roughness in Turning of Metal Matrix Composite Built of Al2O3 Sinter Saturated by Aluminum Alloy in Vacuum Condition. Materials, 15.10.3390/ma15238375 ↗
11. Ganeshkumar, S., Singh, B.K., and Kumar, S.D. (2022). Study of Wear, Stress and Vibration Characteristics of Silicon Carbide Tool Inserts and Nano Multi-Layered Titanium Nitride-Coated Cutting Tool Inserts in Turning of SS304 Steels. Materials, 15.10.3390/ma15227994 ↗
12. The effects of cutting parameters on tool wear during the milling of CFRP composites
13. Tool wear prediction in ultrasonic vibration-assisted drilling of CFRP: A hybrid data-driven physics model-based framework10.1016/j.triboint.2022.107755 ↗
14. Correlating tool wear to intact carbon fibre contacts during drilling of continuous fibre Reinforced Polymers (CFRP)10.1016/j.matpr.2022.03.727 ↗
15. Ozkan, D., Panjan, P., Gok, M.S., and Karaoglanli, A.C. (2020). Experimental study on tool wear and delamination in milling CFRPs with TiAlN-and TiN-coated tools. Coatings, 10.10.3390/coatings10070623 ↗
16. Tool wear monitoring and hole surface quality during CFRP drilling10.1016/j.procir.2014.04.028 ↗
17. Study on tool wear mechanism and cutting performance in helical milling of CFRP with stepped bi-directional milling cutters10.1007/s00170-020-06305-7 ↗
18. Analysis of tool wear, cutting force, surface roughness and machining temperature during finishing operation of ultrasonic assisted milling (UAM) of carbon fibre reinforced plastic (CFRP)10.1016/j.proeng.2017.04.084 ↗
19. Tool wear and its effect on the surface integrity in the machining of fibre-reinforced polymer10.1016/j.compstruct.2018.01.018 ↗
20. Numerical analysis of the influence of tool wear and special cutting geometry when drilling woven CFRPs10.1016/j.compstruct.2015.11.065 ↗
21. Study on tool wear during milling CFRP under dry and chilled air machining10.1016/j.proeng.2017.04.121 ↗
22. Wear characteristics of multi-tooth milling cutter in milling CFRP and its impact on machining performance10.1016/j.jmapro.2022.07.008 ↗
23. Investigation of machining parameters that affects surface roughness and cutting forces in milling of CFRPs with TiAlN and TiN coated carbide cutting tools10.1088/2053-1591/ab30de ↗
24. Influence of milling process parameters on the surface integrity of CFRP10.1016/j.procir.2012.04.083 ↗
25. Design and test of a multitooth tool for CFRP milling10.1177/0021998309345354 ↗
26. Machinability and surface quality during milling CFRP laminates under dry and supercritical CO2-based cryogenic conditions10.1007/s40684-021-00386-9 ↗
27. Cutting performance and wear mechanisms of the graphene-reinforced Al2O3-WC-TiC composite ceramic tool in turning hardened 40Cr steel10.1016/j.ceramint.2022.01.251 ↗
28. Wear mechanism of nanotwinned cBN tools in nano-cutting Ni-Cr-Fe alloy by molecular dynamics simulation10.1016/j.jmapro.2022.07.023 ↗
29. Influence of process parameters on tool wear and temperature of coated HSS tools on drilling of hardened EN8 alloy steel10.1016/j.matpr.2021.09.169 ↗
30. Neutrosophic entropy-based ingenious measurement for fast fourier transforms based classification of process-parameters and wear resistance of friction-stir processed hybrid AA7075- B4C aluminium metal-matrix composites10.1016/j.jmrt.2022.07.026 ↗
31. Analysis of cutting parameters on tool wear in turning of Ti-6Al-4V alloy by multiple linear regression and genetic expression programming methods10.1016/j.measurement.2022.111638 ↗
32. Analysis of characteristics of surface roughness of machined CFRP composites10.3311/PPme.14436 ↗
33. In-process drill wear and breakage monitoring for a machining centre based on cutting force parameters10.1016/0890-6955(92)90035-F ↗
34. Estimating cutting force from rotating and stationary feed motor currents on a milling machine10.1016/S0890-6955(02)00082-2 ↗
35. Cutting force model of longitudinal-torsional ultrasonic-assisted milling Ti-6Al-4V based on tool flank wear10.1016/j.jmatprotec.2021.117042 ↗
36. Milling force modeling of worn tool and tool flank wear recognition in end milling10.1109/TMECH.2014.2363166 ↗
37. Heat effect on the material removal in the machining of fibre-reinforced polymer composites10.1016/j.ijmachtools.2019.01.005 ↗
38. A comparative evaluation of polycrystalline diamond drills in drilling high-strength T800S/250F CFRP10.1016/j.compstruct.2014.06.034 ↗
39. Study on the cutting mechanics characteristics of high-strength UD-CFRP laminates based on orthogonal cutting method10.1016/j.compstruct.2015.05.035 ↗