A Parametric Study on Milling Process of Multi-directional Carbon Fiber Reinforced Plastic (MD-CFRP) Composite Using Nano-solid Dry Lubrication

Abstract

A carbon fiber reinforced plastic (CFRP) composite has been utilized for high-tech industries owing to their superior mechanical properties such as a high strength-to-weight ratio. However, a CFRP composite has anisotropy and non-homogeneity, and these properties can cause defects during machining processes. The objective of this study is to comprehensively analyze influences of process variables on the milling performances of multi-directional carbon fiber reinforced plastic (MD-CFRP) composite. In the process, the nano-solid dry lubrication technology is applied, considering moisture-sensitivity of CFRP. For a parametric study, a series of experiments are conducted based on a design of experiment (DOE) approach. Twenty-seven experimental cases are designed considering three process variables such as a tool geometry, a spindle speed, and a feed rate. Then, the resultant cutting forces, surface quality, tool geometry, and cutting temperature are considered as performance indexes. From the experimental results, it is found that the router shows the best milling performances by reducing cutting forces and surface roughness values by 64.8% and 58.8%, respectively, compared to the two-flute milling tool. The five-flute milling tool is also superior to the two-flute one. In addition, the cutting temperature is measured to study its effect on the milling performances.