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Experimental study on wear laws and mechanisms of end cutting edge in end-milling of carbon fiber reinforced polymer

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A Correction to this article was published on 10 March 2023

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Abstract

End cutting edges of tool determine machining quality of the bottom surface of the slot in end-milling of CFRP. However, due to anisotropy and heterogeneous of CFRP, and also semi-closed characteristic of blind slots, the end cutting edges are more vulnerable to wear than the peripheral edges under the strong abrasive fibers, leading to the poor machining quality of the bottom surface of the slots, and thereby decreases the assembly performance of the components. This paper aims to reveal the wear laws and mechanisms of the end cutting edge which serves under the poor machining conditions in end-milling of CFRP. In order to obtain major wear forms of the end cutting edge, the tool’s structure and the removal characteristics in end-milling of CFRP are analyzed. For acquiring the wear laws accurately, slot-milling experiments are conducted, in which the quantitative characterization of each wear form is proposed. According to the wear laws obtained from the experiments, combining with the associated relationships of each wear form, the wear mechanisms of end cutting edge are revealed, and also, the influences of the tool wear on the surface’s machining quality are got. The results show that there are three wear forms in all including the corner wear, the cutting-edge wear, and the flank wear. Concretely, the corner wear is rapid; the cutting-edge radius is fluctuating and tends to decrease, while the flank face is wearing constantly. The conclusions of this study can provide foundations for further studies on suppression of the tool wear.

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Acknowledgements

The authors wish to thank the anonymous reviewers for their comments which lead to improvements of this paper.

Funding

This work was supported by the Major Program of the National Natural Science Foundation for Young Scholars of China (grant number 52005077) and National Natural Science Foundation of China (grant number 52090053).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Key Laboratory of High-Performance Manufacturing for Advanced Composite Materials, Dalian University of Technology, Dalian, Liaoning Province, China

    Han Mu, Boyu Zhang, Gang Wei, Xiaohang Hu & Fuji Wang

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  1. Han Mu
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  2. Boyu Zhang
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  3. Gang Wei
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  4. Xiaohang Hu
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  5. Fuji Wang
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Boyu Zhang, Gang Wei, and Fuji Wang. The first draft of the manuscript was written by Han Mu and Gang Wei; all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Boyu Zhang.

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Mu, H., Zhang, B., Wei, G. et al. Experimental study on wear laws and mechanisms of end cutting edge in end-milling of carbon fiber reinforced polymer. Int J Adv Manuf Technol 125, 5397–5406 (2023). https://doi.org/10.1007/s00170-023-11023-x

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