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Tool wear and surface quality during milling CFRP laminates under dry and LN2-based cryogenic conditions

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Abstract

Carbon fiber-reinforced plastics (CFRP) are widely used in the aerospace and automobile industries because of their ultralight weight, high strength, excellent corrosion resistance, and anti-fatigue properties. However, the machining of CFRP is still challenging due to its super hardness and sensitivity to heat. Cryogenic milling is a kind of sustainable manufacturing process which is considered to have great potential for processing CFRP. This work is devoted to analyzing the tool wear and surface quality under dry and cryogenic conditions based on liquid nitrogen (LN2) and also provides a reference for selecting parameters of CFRP processing in industries. A series of tests were conducted under various cutting speeds, feed per tooth, and LN2 jet temperatures. In order to reveal the changing laws of tool wear and surface quality, flank wear bandwidth (VB), surface roughness (Sa) and burr factor (Fb) were carried out. The experimental findings have shown that tool wear is suppressed at high cutting speed and feed rate. In addition, surface quality is significantly improved at an appropriate temperature, and burr damage was also effectively suppressed with the temperature dropping, while tool wear is severer at − 196 ℃ than in dry conditions.

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All data generated or analyzed during this study are included in this published manuscript.

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Funding

This work was supported by the National Key R&D Program of China [Grant No. 2020YFB2010600] and the Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics in Nanjing, China.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Xiaoyu Chen, Wei Zhao, Guolong Zhao, Muhammad Jamil & Ning He

  2. Key Laboratory of Science and Technology On Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Wei Zhao

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  1. Xiaoyu Chen
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Contributions

Xiaoyu Chen carried out the experiments and characterization and prepared the original manuscript. Wei Zhao proposed the innovation points and contributed to the discussions. Guolong Zhao checked the experiment results and laid out the structure of the manuscript. Muhammad Jamil contributed to polishing and editing the manuscript. Ning He provided funding support. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Wei Zhao.

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Chen, X., Zhao, W., Zhao, G. et al. Tool wear and surface quality during milling CFRP laminates under dry and LN2-based cryogenic conditions. Int J Adv Manuf Technol 123, 1785–1797 (2022). https://doi.org/10.1007/s00170-022-10234-y

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