Abstract
Machined surface quality determines the reliability, wear resistance and service life of carbon fiber reinforced plastic (CFRP) workpieces. In this work, the formation mechanism of the surface topography and the machining defects of CFRPs are proposed, and the influence of milling parameters and fiber cutting angles on the surface quality of CFRPs is obtained, which can provide a reference for extended tool life and good surface quality. Trimming and slot milling tests of unidirectional CFRP laminates are performed. The surface roughness of the machined surface is measured, and the influence of milling parameters on the surface roughness is analyzed. A regression model for the surface roughness of CFRP milling is established. A significance test of the regression model is conducted. The machined surface topography of milling CFRP unidirectional laminates with different fiber orientations is analyzed, and the effect of fiber cutting angle on the surface topography of the machined surface is presented by using a digital super depth-of-field microscope and scanning electron microscope (SEM). To study the influence of fiber cutting angle on machining defects, the machined topography under different fiber orientations is analyzed. The slot milling defects and their formation mechanism under different fiber cutting angles are investigated.
Highlights
Carbon fiber reinforced plastics (CFRPs) are being extensively used in various fields due to their excellent mechanical properties [1,2]
Surface quality and machining defects play an important role in CFRP milling [9,10,11]
It is seen that feed per tooth f z has the greatest influence on the surface roughness, and the milling width ae has the least influence on the surface roughness
Summary
Carbon fiber reinforced plastics (CFRPs) are being extensively used in various fields due to their excellent mechanical properties [1,2]. The main machining defects in the CFRP milling process include surface fiber burrs, surface fiber tears, and interlayer delamination [12,13]:. As the axial tensile strength of the fiber is greater than the interlayer bonding strength, the fiber layer is separated from the matrix material before tensile fracture, and the tear direction is generally along the surface fiber direction. Interlayer delamination of the machined surface: When the interlayer stress exceeds the interlayer bonding strength and fiber bonding strength in the milling process, debonding will occur between the carbon fiber bundles and matrix material, accompanying the deformation of the fiber layer. Interlayer delamination defects may occur in any fiber layer of the milling fracture [19,20] If they occur on the surface, there will be tear and burrs. The influence of milling parameters and fiber cutting angles on the surface quality of CFRPs is determined and analyzed
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