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Effect of the Fiber Orientation and the Radial Depth of Cut on the Flank Wear in End Milling of CFRP

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Abstract

In this study tool wear during CFRP milling is experimentally investigated to explore the optimization of various cutting condition. From the test machining, it was found that CFRP milling was conducted mostly through the brittle mode machining that creates chip with powder shape. Tool wear is originated from the flank wear generated by the friction force between flank face and machined surface as well as the cutting edge wear by an impact force of fiber cutting. The flank wear is focused on a fiber orientation as well as a friction distance of the flank face in this paper. Based on the results, the tool wear progression model is suggested considering the fiber orientation and the radial depth of cut. From the results, it was found that the fiber orientation greatly affects the flank wear which arises most severely at the parallel to the tool feed direction that induces larger friction force. Also, the radial depth of cut smaller than 10% of diametric engagement accelerates the flank wear due to the increase of friction distance. Using this correlation among parameters, wear prediction model with force equations was derived and estimation results sufficiently match with the wear measurement values.

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Abbreviations

Ft, Ff :

Cutting force (tangential direction, feed direction)

Ktc, Kfc :

Cutting constants (tangential direction, feed direction)

Kte, Kfe :

Cutting edge coefficients (tangential direction, feed direction

h:

Chip thickness

V wear :

Volume of tool wear

K wear :

The wear coefficient

F:

The friction force applied to the contact surface

L:

The friction distance

H:

The wear coefficient

F ra :

Radial cutting force (normal force at the flank face)

W flank :

The flank wear width

β:

The rake angle

γ:

The clearance angle

t z :

The axial depth of the cut

t r :

The radial depth of the cut

r e :

Nose radius

C f :

The tool wear coefficient

D:

The tool diameter

n:

The number of flutes

L d :

The cutting distance

f z :

The feed per tooth

C t :

The tool geometry coefficient

RPM:

The spindle speed (spindle rotation

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Acknowledgements

This work was supported by the Technology Innovation Program (10053248, Development of Manufacturing System for CFRP (Carbon Fiber Reinforced Plastics) Machining) funded By the Ministry of Trade, industry and Energy (MOTIE, Korea), and National Research Foundation of Korea (NRF) granted by the Korea government (MSIT) (Grant No. 2018R1D1A1B07049492).

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  1. School of Mechanical Engineering, Gwangju Institute of Science and Technology, 123, Cheomdangwagi-ro, Buk-gu, Gwangju, 500-712, South Korea

    Minsu Kim, Minkeon Lee, Gihun Cho & Sun-Kyu Lee

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Kim, M., Lee, M., Cho, G. et al. Effect of the Fiber Orientation and the Radial Depth of Cut on the Flank Wear in End Milling of CFRP. Int. J. Precis. Eng. Manuf. 21, 1187–1199 (2020). https://doi.org/10.1007/s12541-020-00340-w

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