Effect of the Cutting Tool on the Quality of a Machined Composite Part

Abstract

The growing use of composite materials in various industries implies the necessity of conducting research on both their manufacture and subsequent machining. One of the main problems in composite machining is the selection of a suitable cutting tool. This study investigates the effect of the geometry and material of a milling cutter on the quality of a milled composite part. A carbon fiber-reinforced epoxy resin matrix composite was tested. Two cutting tools were used: an end mill with PCD inserts with a diameter of 12 mm and the number of teeth of 3 as well as a PCD-coated carbide end mill with a diameter of 12 mm and the number of teeth of 4. Variable technological parameters were used. The quality of the machined surfaces was assessed based on burr height and selected profile roughness parameters. Results showed that for the milling process conducted with the same technological parameters, the surface quality obtained with the 4-tooth PCD-coated carbide tool was higher than that obtained with the 3-tooth tool with PCD inserts.