Wear characteristics of multi-tooth milling cutter in milling CFRP and its impact on machining performance

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

doi:10.1016/j.jmapro.2022.07.008

Cited by 20 publications

(7 citation statements)

References 32 publications

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“…The overall tool wear rate is also influenced by the depth of the cut (Halim et al, 2017). Bi et al (2022) investigated the wear characteristics of uncoated multiple flutes for milling operations. Their research encompassed a range of feeds per tooth, spanning from 0.01 to 0.15 mm/tooth while keeping spindle speed constant at 3000 rpm.…”

Section: Literature Reviewmentioning

confidence: 99%

Effect of Cutting Speed and Feed per Tooth on the Trimmed Surface Roughness and Tool Wear During Milling of CFRP: Aerostructural Part

Sundi,

Abdul Hakim,

Mahadi

et al. 2024

JST

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The machining quality plays a pivotal role in determining the service life of components. In this context, the primary focus of the experimental investigation is centered on the impact of cutting conditions during edge trimming of carbon fiber reinforced plastics (CFRP) material. The ultimate objective of this experiment is to pinpoint the most effective machining parameters, specifically the cutting speed, Vc and the feed per tooth, fz, to minimize damages during the edge trimming process using actual aerostructural sample components composed of CFRP material. Furthermore, the study took into account the issue of tool wear on cutting tools. The Design of Experiment (DoE) technique, specifically the Taguchi L9 orthogonal arrays method, was used to conduct this research. It was shown that the feed per tooth, fz, and the cutting speed, Vc, had the biggest effects on the trimmed surface quality as the longitudinal surface roughness increased. It was demonstrated that the fracture of the pyramidal tooltips in router-type tools happened more frequently at higher cutting speeds, Vc. The optimal machining parameters for minimizing damages during CFRP edge trimming were the combination of the feed per tooth, fz at 0.05 mm and cutting speed, Vc at 50 m/min. The most significant element influencing the tool’s wear was the cutting speed, Vc.

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Section: Literature Reviewmentioning

confidence: 99%

Effect of Cutting Speed and Feed per Tooth on the Trimmed Surface Roughness and Tool Wear During Milling of CFRP: Aerostructural Part

Sundi,

Abdul Hakim,

Mahadi

et al. 2024

JST

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“…To better alleviate damage, many advanced cutting tools have been designed, such as left-right edge mills [25], nicked edge mills [26,27], micro-textured mills [28], various multitooth mills [29,30], and integrated-micro hybrid mills [31]. Multi-tooth mills, in particular, have proven to be effective and economical for slotting or routing CFRP composites, which can achieve minimal cutting depth per tooth to reduce damage [32].…”

Section: Introductionmentioning

confidence: 99%

“…Their left-right edge structure effectively suppresses the top-layer delamination and burrs [25,33]. The excellent side milling quality obtained by multi-tooth mills has attracted considerable research attention [26,29,34]. However, the influence of fibre cutting angles on the bottom slotting surfaces has been rarely reported, especially the insufficient investigation of changes in milling direction, which has been focused on in previous studies of damage behaviours on the side milling surface [34][35][36].…”

Section: Introductionmentioning

confidence: 99%

Influence of Fibre Orientation on the Slotting Quality of CFRP Composites Using the Multi-Tooth Mill

Zhai,

Lv,

Yan

et al. 2024

Materials

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Carbon fibre-reinforced plastic (CFRP) composites, prized for their exceptional properties, often encounter surface quality issues during slotting due to their inherent heterogeneity. This paper tackles CFRP slotting challenges by employing multi-tooth mills in experiments with various fibre orientations and tool feed rates. In-plane scratching tests are performed under linearly varying loads; then, slotting experiments are conducted at different parameters. The scratching test results indicate that the fibre orientation and cutting angles have significant influences on forces and fracture process. The slotting experiments demonstrate that cutting forces and surface roughness Sa of the bottom slotting surface are notably affected by the fibre orientation, with disparities between up-milling and down-milling sides. Reorganising Sa data by local fibre cutting angle θ highlights consistent Sa variations between up-milling and down-milling sides for 0° ≤ θ ≤ 90°, with lower Sa on the up-milling side. However, for 90° < θ ≤ 150°, Sa variations diverge, with lower Sa on the down-milling side. Unexpectedly, Sa on the down-milling side decreases with increasing θ in this range. Additionally, the tool feed rate exerts a more pronounced influence on Sa on the up-milling side.

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“…Using Central Composite Design (CCD), Khairusshima et al [21] found tool wear increased as the cutting speed, feed rate, and depth of cut increased under both dry machining and chilled air machining. Bi et al [22] concluded that feed per tooth is an influential factor in the wear of multi-tooth milling cutters, and burr damages on the top and bottom ply increase with tool wear aggravation. Such studies shed light on the tool wear mechanisms of CFRP composite cutting and offer effective solutions to delay wear.…”

Section: Introductionmentioning

confidence: 99%

Research on Tool Wear and Surface Integrity of CFRPs with Mild Milling Parameters

Qiu

Zhang

et al. 2023

Coatings

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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.

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Wear characteristics of multi-tooth milling cutter in milling CFRP and its impact on machining performance

Cited by 20 publications

References 32 publications

Effect of Cutting Speed and Feed per Tooth on the Trimmed Surface Roughness and Tool Wear During Milling of CFRP: Aerostructural Part

Effect of Cutting Speed and Feed per Tooth on the Trimmed Surface Roughness and Tool Wear During Milling of CFRP: Aerostructural Part

Influence of Fibre Orientation on the Slotting Quality of CFRP Composites Using the Multi-Tooth Mill

Research on Tool Wear and Surface Integrity of CFRPs with Mild Milling Parameters

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