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Study on cutting force and surface quality during slot milling of CFRP based on equivalent milling area

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Abstract

Due to the anisotropy and poor heat dissipation of carbon fiber–reinforced plastics (CFRP), it is easy to produce high cutting force in the machining process, which makes the machined surface quality worse. This paper studies the effects of spindle speed, feed rate, and cutting depth on milling force and surface roughness during slot milling plain-woven CFRP by Taguchi orthogonal experimental design. On the basis of equivalent cutting thickness, the calculation formula of equivalent milling area is established, and the variation of cutting force and surface roughness with equivalent milling area is studied. The results show that the cutting force and surface roughness increase with the increase of equivalent milling area and decrease with the decrease of equivalent milling area. The surface material removal mechanism of CVD tool under different equivalent milling areas is analyzed. The variance analysis of cutting force and surface roughness produced by PCD tool and CVD diamond-coated end mill is carried out. It is found that the spindle speed has the most significant effect on cutting force and surface roughness. In addition, the delamination of the upper surface of the milled groove is closely related to the fiber cutting angle. And when the fiber orientation angle is 0°, the PCD tool can be used for up milling to obtain smaller surface tearing.

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Authors and Affiliations

  1. School of Mechatronics Engineering and Automation, Shanghai University, Shanghai, 200444, China

    Ziyang Xu & Yongguo Wang

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  1. Ziyang Xu
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  2. Yongguo Wang
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Contributions

The first author Ziyang Xu has been responsible for writing this paper, testing and collecting experimental data, analyzing the influence of cutting parameters on cutting force and surface roughness, and studying the removal mechanism of carbon fiber composites processed by PCD tools. The corresponding author Prof. Yongguo Wang provided suggestions, discussions, and review during the manuscript revision process. He is also responsible for determining the overall logical structure of the paper and guiding the entire experiment.

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Correspondence to Yongguo Wang.

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Xu, Z., Wang, Y. Study on cutting force and surface quality during slot milling of CFRP based on equivalent milling area. Int J Adv Manuf Technol 123, 3377–3386 (2022). https://doi.org/10.1007/s00170-022-10411-z

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  • DOI: https://doi.org/10.1007/s00170-022-10411-z

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