Study on wear mechanism of solid carbide cutting tool in milling CFRP
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Che Hassan Che Haron and Jaharah A. Ghani Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, University Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia (Received 6 December 2015; accepted 11 January 2016)
Carbon fiber reinforced plastic (CFRP) is an expensive composite which has become valuable material as the demand for this composite increased in the industries. It is suitable to be used in automotive, aerospace, and aircraft because of its properties which is stronger than steel and also stiffer than titanium while retaining its lighter weight. However machining of CFRP is a mess to machinist due to its nature which is abrasive. The paper presents the wear mechanism on solid carbide cutting tool during milling CFRP. The wear mechanism is observed under dry and chilled air machining. The machining parameters tested were at cutting speed of 200 m/min with constant feed rate and depth of cut. For both dry and chilled air machining, it is observed that carbide cutting tool experienced abrasive wear which has been influenced by abrasive powdering chips and fibers during milling CFRP. Under microscope and scanning electron microscope, the abrasive wear is represented by shiny and polish area on the cutting tool respectively. This abrasive wear is observed higher under dry machining compared to the chilled air machining which was due to the heat generated during machining. Thus, chilled air has a potential of improving machinability of CFRP by using solid carbide cutting tool.
I. INTRODUCTION
Lately, there has been a growing need for material which has characteristic of lightweight, high strength, low density, high stiffness, and good corrosion resistance. The material which also practices low friction coefficient and has stable dimensionally (about zero coefficient of thermal expansion) is also in advantage to the industries.1 Carbon fiber reinforced plastic (CFRP) is one of the composite which exhibit all these special physical and mechanical properties. It is stronger than steel, has lower density than aluminum and stiffer than titanium, while still retaining its lighter weight makes them suitable to replace several conventional materials in various applications.2,3 In aerospace industries, CFRP has been used as primary structural materials. It has been used in rocket exit nozzles, nose caps, pistons for internal combustion engines, and fusion devices. In aircraft application, to reduce the weight of structural components on the aircraft CFRP are commonly used which resulted in improved fuel economy, reduced emissions, and increased load carrying capacity of the aircraft. This composite has also been acknowledged as Contributing Editor: Mohd Fadzli Bin Abdollah a) Address all correspondence to this author. e-mail: [email protected] DOI: 10.1557/jmr.2016.21
a highly promising material for the applications in aeronautics, oil and gas, automotive, and medical industries.4,5 The CFRP composites are generally fabricated by various processes such as hand lay-up an
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