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Comparative study on cutting performance of conventional and ultrasonic-assisted bi-directional helical milling of CFRP

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Abstract

Compared with the conventional drilling, the helical milling has obvious advantages in making holes of carbon fiber-reinforced plastic (CFRP). Nevertheless, the rapid wear of cutting edges readily causes some defects in the outlet holes, such as burrs and tearing. In order to improve the hole-making quality of CFRP, a comparative experimental study on conventional and ultrasonic-assisted bi-directional helical milling of CFRP was carried out. The wear mechanism of the forward and reverse cutting edges was analyzed in the two types of machining, and the change laws of cutting forces and hole wall quality were obtained by different machining means. The experimental results indicated that the flank face of forward and reverse cutting edges was dominated by the abrasive wear mechanism in the ultrasonic-assisted milling. With aggravation of the tool wear, no obvious coating peeled off the forward cutting edge, the reverse cutting edge remained relatively intact, and the wear form of neither cutting edge changed. Furthermore, in the ultrasonic-assisted reverse milling, the axial force and hole diameter deviation were restrained better than in the conventional milling, and especially when the tool wear occurred, the cutting force fluctuation varied slowly. In the ultrasonic-assisted milling, the shear fracture predominated over bending fracture. Meanwhile, the time variation of effective rake angles improved the chip breaking and removing performance of cutters, and thus, the machining quality of hole wall was enhanced obviously.

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The raw/processed data required to reproduce these findings cannot be shared for the time being. Data will be made available upon request.

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Funding

This work was financially supported by the National Natural Science Foundation of China (Grant No. 51975168), and the Shanghai Natural Science Foundation (Grant No.18ZR1441000).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin, 150080, China

    Chen Tao, Lu Yujiang, Wang Yongsheng & Liu Gang

  2. School of Mechanical Engineering, Tongji University, Shanghai, 200092, People’s Republic of China

    Liu Guangjun

Authors
  1. Chen Tao
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  2. Lu Yujiang
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  3. Wang Yongsheng
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  4. Liu Gang
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  5. Liu Guangjun
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Contributions

Chen Tao has organized the project, designed the experiments, and written the manuscript; Lu Yujiang has conducted the experiments, and collected and analyzed data; Wang Yongsheng has designed the experiments, analyzed and arranged data, and written the manuscript; Liu Gang has conducted the experiments, and collected and analyzed data; and Liu Guangjun has reviewed the manuscript.

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Correspondence to Chen Tao.

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Tao, C., Yujiang, L., Yongsheng, W. et al. Comparative study on cutting performance of conventional and ultrasonic-assisted bi-directional helical milling of CFRP. Int J Adv Manuf Technol 115, 3701–3711 (2021). https://doi.org/10.1007/s00170-021-07418-3

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