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

Wang, Fuji; Chen, Peizhe; Fu, Rao; Bi, Guangjian

doi:10.1177/09544054221130396

Cited by 3 publications

(1 citation statement)

References 31 publications

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“…Increase the cutting speed to reduce cutting forces values is the most frequent method used by researchers. 18,21,[46][47][48][49] High temperature at the flow zone increased hardens of coating and decreased tool-chip contact area, except for uncoated cutting tool, which is considered to be the main reasons of this inverse proportion. Furthermore, the reduction amount in cutting forces can depend on workpiece material, working conditions, and ranges of cutting velocities.…”

Section: Cutting and Feed Forcesmentioning

confidence: 99%

Experimental investigation of uncoated, single layer, and multilayer-coated TiAlN/TiN tool inserts in dry orthogonal cutting of AISI/SAE 4140 alloy steel

Akbar

Arsalan

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Significant temperature rise is stimulated during high-speed machining of metals, specifically in dry cutting conditions. This experimental investigation undertakes the effects of uncoated, single layer coatings (TiN and TiAlN), and multilayer coatings [TiAlN/TiN (9 + 5 µm), (9 + 3 µm), (9 + 1 µm), and (5 + 1 µm)] on cutting tool material during dry orthogonal cutting of AISI/SAE 4140 alloy steel. The study compares crucial parameters such as cutting and feed forces, chip-tool contact area, thickness of deformed chip, chip reduction coefficient, heat partition ratio, flank wear, and shear angle. The layer TiAlN used as the first layer from the Tungsten Carbide (WC) substrate owing to its better adhesion property, whereas TiN used as the second layer (top coating) owing to its better sliding behavior. In this research, cutting operations have carried out using Dean Smith and Grace Lathe machine. A Scanning Electron Microscope (SEM) also used along with a Kistler 9263 dynamometer to measure cutting forces. The cutting temperatures are measured with the help of an infrared, high-resolution thermal imaging camera, ThermaCAM model SC3000 by FLIR. Results have shown that layers act as a thermal barrier that block excessive heat generation in the cutting tool. Thus, this increasing the surface finish, tool life, and overall efficiency, while reducing the abrasive wear, tear, and parallel ridges due to rubbing friction. Furthermore, it has found that multilayer coating of (9 + 5 = 14 µm) shown good consistent results with less variance, specifically in the high-speed machining regions. Hence, the study evidently justifies the usage of coated tool inserts in high-speed dry cutting operations.

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Section: Cutting and Feed Forcesmentioning

confidence: 99%

Experimental investigation of uncoated, single layer, and multilayer-coated TiAlN/TiN tool inserts in dry orthogonal cutting of AISI/SAE 4140 alloy steel

Akbar

Arsalan

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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A review on the machining of polymer composites reinforced with carbon (CFRP), glass (GFRP), and natural fibers (NFRP)

Slamani

Châtelain

2023

Discov Mechanical Engineering

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Composite material consumption is booming and is expected to increase exponentially in many industrial applications such as aerospace, automotive, marine and defense. However, in most cases, composite products require further processing before they can be used or assembled. Machining of composite materials is extremely difficult due to their anisotropic and non-homogeneous structure. This paper provides a comprehensive review of the literature on composite materials and their machining processes, such as turning, milling and drilling. Damage related to these processes is also discussed. The paper is divided into seven main parts; the first, second and third parts give a brief overview of composite materials, reinforcements used in composite materials and composite manufacturing methods, respectively. The fourth part deals with post-processing machining operations, while the fifth, sixth and seventh parts are devoted to the machining of carbon fiber reinforced polymer composite, glass fiber reinforced polymer and natural fiber reinforced polymer composites, respectively. An analysis of the factors that influence the machining and the machinability criteria used for these materials is also presented, with particular emphasis on cutting forces, tool wear, delamination and surface finish. Non-traditional manufacturing methods are not discussed in this paper.

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A comparative study on milling-induced surface roughness during milling of jute–epoxy and carbon–epoxy composites and optimization for better surface finish through Taguchi and RSM techniques

B. R. N.,

Hiremath,

Giri

et al. 2024

AIP Advances

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During the present experimentation, milling machining was performed on two different composites, namely carbon fiber-reinforced polymer composite and jute fiber-reinforced polymer composite, using a computer numerical control vertical machining center. The selected machining parameters were spindle speed (S), feed rate (FR), depth of cut (DOC), and flute number or cutting edge number (FN). The output parameter is the machined surface roughness (Ra). Analysis of variance was used to predict the percentage influence of each parameter on machining quality. The parameter feed rate exhibited a higher influence on the machined surface roughness, followed by spindle speed, flute number, and depth of cut in sequence. Similarly, while milling the carbon fiber composite, the feed rate had the highest influence, followed by the parameter flute number. As for the surface roughness, the feed rate had a greater effect, followed by the spindle speed. Under the same machining conditions, it was observed that the sequence of parameters influencing the jute composite and carbon composite changed in the case of cutting force generation, but the sequence of parameters was the same for both cases in terms of roughness. The outcome of the work confirmed that to achieve a smaller value of roughness in the milling of jute–epoxy composite, the optimum combination should be S = 3000 rpm, FR = 800 mm/min, DOC = 0.25 mm, and FN = 6. Similarly, to achieve the minimum surface roughness value in the milling of carbon–epoxy composite, the optimum combination of parameters should be S = 600 rpm, FR = 100 mm/min, DOC = 0.25, and FN = 6. The average roughness values obtained during the milling of jute–epoxy composite and carbon–epoxy composites are 6.685 and 3.08 μm, respectively. In this present work, it is proved that the optimum combination of parameters to get the minimum surface roughness and the amount of surface roughness produced during milling are highly influenced by the type of reinforced material. The graphs are prepared for the entire range of input parameters to identify the intermediate Ra value at any input value without the use of software.

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

Cited by 3 publications

References 31 publications

Experimental investigation of uncoated, single layer, and multilayer-coated TiAlN/TiN tool inserts in dry orthogonal cutting of AISI/SAE 4140 alloy steel

Experimental investigation of uncoated, single layer, and multilayer-coated TiAlN/TiN tool inserts in dry orthogonal cutting of AISI/SAE 4140 alloy steel

A review on the machining of polymer composites reinforced with carbon (CFRP), glass (GFRP), and natural fibers (NFRP)

A comparative study on milling-induced surface roughness during milling of jute–epoxy and carbon–epoxy composites and optimization for better surface finish through Taguchi and RSM techniques

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