Abstract
PurposeSurface roughness and delamination during the milling of carbon fiber reinforced polymer (CFRP) composite parts in aviation can lead to component rejection. This article aims to optimize cutting conditions to reduce these failures while ensuring compliance with aviation standards. By improving machinability, the goal is to minimize part rejection rates and scrap, optimizing costs and increasing safety.Design/methodology/approachFull factorial experimental design and response surface methodology (RSM) were used to establish relationships between the cutting parameters and the cutting force, delamination and surface roughness. To validate the model and identify significant parameters, analysis of variance (ANOVA) was performed. The cutting parameters were optimized to reduce cutting force and improve surface quality using ANOVA and RSM.FindingsThe lowest response values can be achieved with a cutting speed of 285.35 m/min and a feed of 358.57 mm/min using the Aluminum Chromium Nitride (AlCrN)-coated tool. Accordingly, the optimum cutting force was obtained as 190.97 N, delamination depth as 1.562 mm and surface roughness as 1.431 µm. It has been seen that the obtained surface roughness and delamination values are consistent with aviation literature studies, sectoral data and standards.Originality/valueThis study uniquely examines cutting force, surface roughness and delamination using Titanium Aluminum Nitride (TiAlN)- and AlCrN-coated tools instead of traditional Poly Cyristaline Diamond (PCD) tools. It employs a two-stage experimental framework, starting with a full factorial design followed by RSM. The initial data have been used as inputs for optimization in the second stage to achieve more accurate results.
Published Version
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