Optimization of multi-tooth milling tool for interlaminar damage suppression in the milling of carbon fiber–reinforced polymers

材料科学 螺旋角 复合材料 机械加工 前角 金刚石工具 碳纤维增强聚合物 涂层 聚合物 沟槽(工程) 各向异性 模数 有限元法 钻石 结构工程 金刚石车削 复合数 冶金 工程类 物理 量子力学
作者
Jian Liu,Xinkai Tang,Shipeng Li,Xuda Qin,Hao Li,Weizhou Wu,Yadav Srijana,Wentao Li,Haibao Liu
出处
期刊:The International Journal of Advanced Manufacturing Technology [Springer Science+Business Media]
卷期号:121 (1-2): 1235-1251 被引量:2
标识
DOI:10.1007/s00170-022-09369-9
摘要

Carbon fiber–reinforced polymers (CFRP) are widely utilized in the aerospace field due to their significant specific strength, specific modulus, and strong design ability. However, anisotropy and low interlaminar bonding strength lead to burr, tear, lamination, and other damages in CFRP machining. In this paper, a 3D finite element model for the milling of CFRP was carefully developed, and the cutting forces, the interlaminar stress, and the interlaminar damage were properly obtained. Typically based on the developed model, the effects of geometric parameters of the multi-tooth milling tool were precisely analyzed. Next tool geometries were optimized for suppressing the interlaminar damage in the milling of CFRP. Results convincingly show that the multi-tooth milling tool with the geometry of 1.4 mm length of the micro tooth, 38.2° left helix angle, 11 left-handed chip grooves, 15° right helix angle, 12 right-handed helix grooves, approximately rectangular of section shape of the chip groove, 10° rake angle, and 15° clearance angle efficiently delivers the optimal performance. Besides, cutting performance of numerous coated tools was also studied. Results typically show that the multi-tooth milling tool with a diamond coating maintains significant advantages in aspects of the tool life and costs compared with the uncoated and diamond-like carbon coating (DLC)-coated tools.
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