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Influence of process parameters on material removal during surface milling of curved carbon fiber-reinforced plastic (CFRP) components: evaluated by a novel residual height calculation method

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Abstract

During the surface milling process, the curved surface components, which were made of carbon fiber-reinforced plastics (CFRP), were prone to complex deformations. These resulted in ineffective material removal, thereby inducing undesirable damages. To address this problem, the present study analyzed the material removal process during the curved surface milling of CFRP components. A novel residual height calculation method, considering the deformation of the curved CFRP surface components, was initially proposed, to describe the material removal quality quantificationally. After applying this method for CFRP cylindrical components, surface milling experiments were conducted, and the influences of the process parameters on material removal were analyzed. Results suggested that reducing the axial cutting depth and the tool feed resulted in better surface appearance and less machining damage of the curved CFRP surfaces, while increasing the spindle speed reduced the machining damage only, but had little effect on the surface appearance. The findings of the present study facilitated the understanding of the material removal law in the surface milling processes of curved CFRP surface components, and also provided foundations for improving milling quality.

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Data Availability

The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Funding

This work was supported by the National Key R&D Program of China (Grant No. 2018YFA0702803); The Major Program of the National Natural Science Foundation of China (grant number 52090053); National Natural Science Foundation for Young Scholars of China (grant number 52005077); Liaoning Revitalization Talents Program (Grant Nos. XLYC1902014, XLYC1801008, and XLYCYSZX1901); and Fundamental Research Funds for the Central Universities.

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, Department of Mechanical Engineering, Dalian University of Technology, Dalian, China

    Fuji Wang, Yue Li, Boyu Zhang, Junfeng Fan, Lelin Yang & Yongquan Lin

Authors
  1. Fuji Wang
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  2. Yue Li
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  3. Boyu Zhang
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  4. Junfeng Fan
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  5. Lelin Yang
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  6. Yongquan Lin
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Contributions

Fuji Wang and Yue Li conceived and designed the study. Yue Li and Junfeng Fan performed the experiments. Yue Li and Boyu Zhang wrote the paper. Boyu Zhang, Lelin Yang, and Yongquan Lin reviewed and edited the manuscript. All authors read and approved the manuscript.

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Correspondence to Boyu Zhang.

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Wang, F., Li, Y., Zhang, B. et al. Influence of process parameters on material removal during surface milling of curved carbon fiber-reinforced plastic (CFRP) components: evaluated by a novel residual height calculation method. Int J Adv Manuf Technol 116, 3405–3415 (2021). https://doi.org/10.1007/s00170-021-07590-6

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