Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

Abstract

This work aims to study the influence of cutting parameters (cutting speed, feed rate, cutting depth and tool cutting edge angle) regarding surface roughness and burr formation during the milling of a mixed structure comprised of titanium and carbon fiber (stack). The parameters were varied from maximum to minimum, just as the tool cutting edge angle of the insert, through a full factorial design with 32 trials. The analyses were performed by measuring the surface roughness and burr size along with metallographic analyses through optic microscopy and scanning electron microscopy. The results showed that the surface roughness was higher for carbon fiber and burr size was higher for titanium. There were a number of tests with delamination of the carbon fiber, and the best cutting parameters to minimize surface roughness and burr formation were tool cutting edge angle of 45º, a feed rate of 0.028 mm/tooth, cutting depth equal to 0.26 mm and cutting speed equal to 150 m/min.

Evaluation and multi-criteria optimization of surface roughness, deviation from dimensional accuracy and roundness error in drilling CFRP/Ti6Al4 stacks

“…Shyha et al analyzed hole quality/integrity after drilling titanium/CFRP/aluminum stacks under flood coolant and spray mist environments [29]. Ashmawi et al investigated the effect of cutting parameters on surface roughness and burr formation during milling a stack of Ti and CFRP [30]. Chashchin et al explained the effects of cutting parameters on hole accuracy in drilling hybrid stacks and offered suggestions for optimizing the cutting parameters [31].…”

Surface Roughness after Milling of the Al/CFRP Stacks with a Diamond Tool

“…A literature analysis shows that most of the attention is focused on investigating the machinability of fibre composites (mainly CFRP) and the quality of holes made in hybrid sandwich structures [7,8]. In [9], the effects of cutting speed, feed, and depth of cut and cutting tool blade angle on the surface roughness and formation of burrs during milling of Ti/CFRP structures were investigated. It was demonstrated that the CFRP layer had a higher surface roughness, while the Ti layer had a higher proportion of burrs.…”