Understanding the tool wear mechanism during robotic milling of glass fibre reinforced plastic

Abstract

Glass fiber reinforced plastics (GFRP) are widely appiled for high-value components, but it faces limitations due to the heterogeneity and limited milling tool life. This study investigates the wear mechanism of tools in varying states of wear during the milling of GFRP under different combinations of cutting parameters. The findings demonstrate a significant increase in flank wear values of new tools, initially worn tools, moderate worn tools and severely worn tools associated with the large material removal rate (LMRR), exhibiting respective increments of 56.7%, 59.8%, 74.3%, and 26.5% in contrast to the small material removal rate (SMRR). The wear mechanisms in distinct cutting regions of the tool were systematically classified and characterized. The flank face and tool nose primarily experience abrasion and adhesion, while the rake face and cutting edge predominantly display characteristics of microchipping and abrasive wear. In contrast, the bottom edge is exclusively impacted by microchipping. The deposition of chemical elements on the cutting edge was examined through electron dispersive spectroscopy (EDS) and scanning electron microscopy (SEM). A comprehensive investigation was undertaken to elucidate the progression of tool wear. The findings indicate that the principal factors influencing tool wear in LMRR are adhesive wear resulting from cutting heat and chipping wear arising from substantial cutting loads. In contrast, tool wear during SMRR is predominantly attributed to abrasive wear caused by the presence of fiber-based hard points within GFRP workpieces. The wear characteristics of milling tools during the machining of GFRP are systematically investigated and analyzed. This study holds theoretical significance in guiding the design of tool materials for GFRP milling operations.