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Optimization of multi-tooth milling tool for interlaminar damage suppression in the milling of carbon fiber–reinforced polymers

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Abstract

Carbon fiber–reinforced polymers (CFRP) are widely utilized in the aerospace field due to their significant specific strength, specific modulus, and strong design ability. However, anisotropy and low interlaminar bonding strength lead to burr, tear, lamination, and other damages in CFRP machining. In this paper, a 3D finite element model for the milling of CFRP was carefully developed, and the cutting forces, the interlaminar stress, and the interlaminar damage were properly obtained. Typically based on the developed model, the effects of geometric parameters of the multi-tooth milling tool were precisely analyzed. Next tool geometries were optimized for suppressing the interlaminar damage in the milling of CFRP. Results convincingly show that the multi-tooth milling tool with the geometry of 1.4 mm length of the micro tooth, 38.2° left helix angle, 11 left-handed chip grooves, 15° right helix angle, 12 right-handed helix grooves, approximately rectangular of section shape of the chip groove, 10° rake angle, and 15° clearance angle efficiently delivers the optimal performance. Besides, cutting performance of numerous coated tools was also studied. Results typically show that the multi-tooth milling tool with a diamond coating maintains significant advantages in aspects of the tool life and costs compared with the uncoated and diamond-like carbon coating (DLC)-coated tools.

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Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

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Funding

The authors would like to acknowledge the financial support received from the Natural Science Foundation of China (Nos. 52075380 and 51775373) and the Natural Science Foundation of Tianjin (No. 19JCYBJC19000).

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Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin, 300354, China

    Jian Liu, Xinkai Tang, Shipeng Li, Xuda Qin, Hao Li, Weizhou Wu, Yadav Srijana & Wentao Liu

  2. China Helicopter Research and Development Institute, Jingdezhen, 333000, China

    Xinkai Tang

  3. Centre for Aeronautics, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield, MK43 0AL, UK

    Haibao Liu

Authors
  1. Jian Liu
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  2. Xinkai Tang
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  3. Shipeng Li
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  4. Xuda Qin
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  5. Hao Li
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  6. Weizhou Wu
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  7. Yadav Srijana
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  8. Wentao Liu
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  9. Haibao Liu
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Contributions

Jian Liu: investigation, experimental design, data analysis, writing, and editing. Xinkai Tang: finite element model, numerical and experimental data analysis, writing, and editing. Shipeng Li: investigation, preparation of experimental materials, review, and editing. Xuda Qin: investigation, preparation of experimental materials, review, and editing. Hao Li: review and editing. Weizhou Wu: review and editing. Yadav Srijana: review and editing. Wentao Liu: review and editing. Haibao Liu: review and editing.

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Correspondence to Shipeng Li.

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Liu, J., Tang, X., Li, S. et al. Optimization of multi-tooth milling tool for interlaminar damage suppression in the milling of carbon fiber–reinforced polymers. Int J Adv Manuf Technol 121, 1235–1251 (2022). https://doi.org/10.1007/s00170-022-09369-9

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  • DOI: https://doi.org/10.1007/s00170-022-09369-9

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