Investigation on tearing damage of CFRP circular cell honeycomb in end-face grinding

Abstract

CFRP circular cell honeycomb has promising applications in the aerospace field due to its excellent mechanical properties. However, a large number of periodically distributed tearing damages severely restrict the high-quality machining of CFRP circular cell honeycomb. This paper investigates the formation mechanism of tearing damages during end-face grinding of CFRP circular cell honeycomb and proposes suppression strategies. In this paper, a maximum undeformed chip thickness model considering tearing damage distribution is developed, and the evolution behavior of tearing damage is studied by combining the material removal process and grinding force. The grinding force and maximum tearing damage depth in different grinding conditions are analyzed. The results show that the formation of tearing damage in the cut-in stage is related to the weak stiffness of thin walls and the radial grinding force. The radial grinding force and maximum tearing depth can be altered by changing the maximum undeformed chip thickness which can be adjusted for different grinding speeds, feed rates, and offset ratios. The low-damage machining of CFRP circular cell honeycomb can be achieved by using a large offset ratio and variable feed rate.