Study on tool wear mechanism and cutting performance in helical milling of CFRP with stepped bi-directional milling cutt
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ORIGINAL ARTICLE
Study on tool wear mechanism and cutting performance in helical milling of CFRP with stepped bi-directional milling cutters Tao Chen 1 & Changhong Wang 1 & Jiupeng Xiang 1 & Yongsheng Wang 1 Received: 28 July 2020 / Accepted: 19 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Helical milling, a new machining technology, has obvious advantages in hole making of carbon fiber reinforced plastic (CFRP), and the technology, nonetheless, shows some defects such as hole diameter tolerance and surface damage aggravation caused by fast tool wear. Aiming to improve the hole making quality of CFRP, this paper proposes the bi-directional helical milling strategy, carries out the experimental research on milling CFRP with stepped bi-directional milling cutters, analyzes the wear mechanism of forward and backward cutting edges, and thus obtains the change laws of cutting forces and hole-making quality in different tool wear conditions. The experimental results show that in the initial milling stage, strip-shaped and spoon-shaped wear bands are formed by abrasive wear mechanism on both forward and backward cutting edges; with aggravation of the tool wear, the wear mechanism of forward cutting edge is gradually dominated by the fatigue wear, and subsequently, a large-area coating peels off the tool surface, causing the rapid wear of substrate. Compared with the forward cutting edge, the backward cutting edge produces less and more stable axial cutting force, and causes all the cutting forces to rise more slowly. In comparison with traditional drilling and milling of CFRP, bi-directional hole-making can effectively suppress some defects such as hole diameter shrinking, burrs and tearing, and thus it shows better machining quality. Keywords Carbon fiber reinforced plastic . Stepped bi-directional milling cutter . Helical milling . Tool wear . Surface quality
1 Introduction Due to its good physical performance such as high specific strength, fatigue and corrosion resistance, CFRP is increasingly used to manufacture key parts in aviation, aerospace and national defense [1, 2]. In order to enhance the hole making quality of traditional drilling, the helical milling technology is invented, showing lots of advantages such as less axial cutting force, large chipremoval space, low cutting temperature and accurate hole making [3]. Nonetheless, some technological issues stand out in helical milling of CFRP, such as too fast tool wear, causing hole diameter deviation and serious surface damage [4, 5]. Widespread popularization and application of helical milling technology in machining
* Tao Chen [email protected] 1
School of Mechanical and Power Engineering, Harbin University of Science and Technology, Harbin 150080, China
CFRP is in sore need of enhancing hole-making quality by improving machining process, designing new-type cutting tools and evaluating their cutting performance. Brinksmeier et al. [6] carried out research on the dynamic characteristics of hole making by helical milli
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