Abstract
This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process.
Highlights
The use of a carbon fiber reinforced polymer (CFRP) has considerably increased in the last few years
The highly abrasive nature of the carbon fibers and the low thermal conductivity of the resin matrix lead to rapid tool wear; the laminated structure of the CFRP facilitates delamination as plies are subject to separation by cutting forces during machining [9,10]
The results showed that when the cutting speed was increased from 40 to 200 m/min at a fixed feed rate of 0.05 mm/rev, the average flank surface temperature increased from 120 to 300 ◦C
Summary
The use of a carbon fiber reinforced polymer (CFRP) has considerably increased in the last few years. Regarding the influence of the tool geometry, it has been observed that the amount or number of harmful particles measured, when using four flutes end mills, is 150 and 120% superior to those generated when trimming is conducted with coated and uncoated burr tools [37] These results have been attributed to the fact that, once the burr tools are used, the temperature of machining is superior. The present work is primarily motivated by the need to focus on the interaction effect of cutting parameters (cutting speed and feed rate) on the following machining process performance indicators: cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission (in terms of number of particles) during dry milling of CFRP.
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