Abstract
Carbon fiber-reinforced plastics (CFRPs) and titanium alloys have different mechanical properties and show the unique processing characteristics in the cutting process. In order to complete hole-making of CFRP/Ti stacks with larger thickness, a comparative study was conducted on the stacks of CFRP/Ti versus CFRP and titanium alloy single plate in the helical milling process. Experimental results show that cutting performance including cutting force and tool wear pattern and hole quality in helical milling of stacks are all different to single plate. The impact of tool wear on the cutting force is relatively significant while machining of CFRP compared to titanium alloy. While machining of CFRP/Ti stacks, axial forces of titanium alloy suddenly change very larger than single titanium plate due to tool wear, and tool wear state shows combination of several wear pattern. Undersized CFRP holes and oversized Ti plate holes are produced when milling single plate; however, oversized CFRP and undersized Ti plate holes are observed when machining of stacks. The results also indicate that tool wear in helical milling of CFRP will influence the cutting performance of stacks.
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