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Indexed by:期刊论文

Date of Publication:2017-07-01

Journal:JOURNAL OF COMPOSITE MATERIALS

Included Journals:SCIE、EI、Scopus

Volume:51

Issue:16

Page Number:2277-2290

ISSN No.:0021-9983

Key Words:Milling of carbon-fiber-reinforced plastic; deterioration of polycrystalline diamond tool; tool-material interaction; burrs; tool life

Abstract:The cutting edge of the polycrystalline diamond tool easily blunts in high-speed milling of carbon-fiber-reinforced plastic with the tool deterioration. It aggravates the burrs damage due to the change in the tool-material interaction. Therefore, this paper analyzes the tool-material interaction in milling of carbon-fiber-reinforced plastic based on the material-removal mechanism to investigate the tool deterioration mechanism. It reveals that there are two main reasons for the tool deterioration: the extreme crashing and ploughing of the uncut fibers on the tool, and the serious impact of fibers strongly supported on the cutting edge. An indirect measure method is proposed to quantify the tool deterioration including the ploughing-caused wear and impact-caused microchipping. Furthermore, the milling tests are performed to evaluate the tool deterioration under different cutting speeds in the range of 7.33-9.42m/s. Meanwhile, a modified mathematical model of tool life is proposed based on a strict burr specification in milling of the carbon-fiber-reinforced plastics. Polycrystalline diamond tool has the longest life with the run-in wear and the quasi-steady-state wear for 7.33m/s cutting speed, and the life rapidly decreases with the increase in the cutting speed in this range. For the cutting speed larger than 8.37m/s, the wear resistance of polycrystalline diamond tool is very low, because the accelerated state wear occurs instead of the quasi-steady-state wear. Thus, the optimization of the tool geometry and the assisted lubrication should be applied for its improvement.