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Planning of cutting tool feed direction for low-damage surface milling of CFRP: considering the changes in the action form of the tool edge on fiber

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Abstract

Surface milling is an extensively adopted post-processing technique for the assembly of carbon fiber–reinforced polymers (CFRPs) with accurate surfaces. However, CFRPs are hard-to-cut materials due to their anisotropic and laminating characteristics that frequently induce machining damages, such as burrs and interface cracks. During surface milling, the action form at any point on the tool edge on the fiber changes with the rotation of the tool and the cutting tool feeding direction, resulting in varying levels of damage in different machining areas. To ensure the high milling quality of CFRP surfaces, this study established a planning method for cutting tool feed direction for low-damage machining by accounting for the changes in the tool edge and fiber action form during CFRP surface milling. The optimal cutting tool feed direction selection range for low-damage surface milling of CFRP components was determined by calculating the changes in the instantaneous fiber cutting angle and length for different cutting tool feed directions and then analyzing the influence of different cutting tool feed directions on the degree of processing damage of CFRP components. The results indicated that to reduce the burr and interfacial cracking damage in the surface milling of CFRP components, the cutting tool feed direction should be selected from the range 0°–40° relative to the fiber ply direction of the final cutting layer. The results obtained in this study can help determine the cutting tool feed direction for the low-damage surface milling of CFRP components and provide a basis for subsequent research on tool path planning.

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

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Funding

This work is supported by National Key R&D Program of China (Grant No. 2018YFA0702803); National Natural Science Foundation of China (Grant Nos. 52090053 and 52105432); Science and Technology Innovation Foundation of Dalian (Grant Nos. 2021RD08 and 2022JJ12GX027); Program: for Liaoning: Innovative Talents In University (XLYC1902014, XLYCYSZX1901); and Fundamental Research Funds for the Central Universities (Grant No. DUT21RC(3)002, DUT21ZD408).

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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, Lelin Yang, Yue Li, Jun Deng, Yongquan Lin, Qingsong He & Rao Fu

Authors
  1. Fuji Wang
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  2. Lelin Yang
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  3. Yue Li
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  4. Jun Deng
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  5. Yongquan Lin
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  6. Qingsong He
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  7. Rao Fu
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Contributions

Fuji Wang and Lelin Yang conceived and designed the study. Lelin Yang and Yue Li performed the experiments. Yue Li and Jun Deng wrote the paper. Yongquan Lin, Qingsong He, and Rao Fu reviewed and edited the manuscript. All authors read and approved the manuscript.

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Correspondence to Fuji Wang.

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Wang, F., Yang, L., Li, Y. et al. Planning of cutting tool feed direction for low-damage surface milling of CFRP: considering the changes in the action form of the tool edge on fiber. Int J Adv Manuf Technol 128, 5101–5116 (2023). https://doi.org/10.1007/s00170-023-12148-9

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  • DOI: https://doi.org/10.1007/s00170-023-12148-9

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