Influence of Machining Parameters on the Milling Quality of T800 CFRP

doi:10.12382/bgxb.2021.0857

Abstract

Abstract:

For large carbon fiber composite components used in aviation, increasing layer thickness and adding sacrificial layers are promising measures for controlling the deformation and improving assembly accuracy. However, milling a large number of sacrificial layers with high efficiency and no delamination damage is challenging. It is difficult to ensure that both the soft glass fiber protective layer on the surface and the hard carbon fiber composite sacrificial layers inside are free of burrs and delamination during the milling process. In this study, T800 carbon fiber reinforced polymer is used in a large aviation component as the research object. Milling experiments are carried out to analyze the effects of different machining parameters on milling quality, such as milling force, milling temperature, and machined surface roughness using four different structural tools. The experimental results indicate that the burr height of the machined surface decreases with the increase of spindle speed. When the feed speed and radial cutting depth increase, the burr height tends to increase. Higher milling temperature causes the deviation of fiber fracture position and increases the surface roughness. On the premise of ensuring the machining quality of carbon fiber composites, the sharp edge shape and multi micro edge milling method can significantly restrain the burr damages. The cutter with left-hand and right-hand micro edge structures make the milling process more stable.

Key words: T800 Carbon fiber reinforced polymer/plastic, burr, machining parameters, multi-edge micro element milling

GAO Hang, LAN Baohua, XU Qihao, CHEN Liangzi, XIAO Guangming. Influence of Machining Parameters on the Milling Quality of T800 CFRP[J]. Acta Armamentarii, 2023, 44(4): 994-1005.

Figures/Tables 19

Fig.1 Test principle

Fig.2 Test site

Fig.3 Test material and paving angle of the first 21 layers

Fig.4 Test tools

Table 1 Geometric parameters of the tools

刀具	前角/ (°)	后角/ (°)	左螺旋角/ (°)	右螺旋角/ (°)	齿数	直径/ mm	刀刃区域长度/mm	总长度/ mm
玉米铣刀	6	12	114	64	16	10	28	63
涂层铣刀	8	11	136	76	12	10	22	75
复合铣刀	5	9	128	40	4	10	30	80
PCD铣刀	3	10		86	2	10	16	73

Table 2 Single-factor test parameters

水平	n/(r·min^-1)	f/(mm·min^-1)	a_e/mm
1	5000	200	1.0
2	7000	300	1.5
3	8000	400	2.5
4	10000	500	3.0

Fig.5 Position for burr measurement

Fig.6 z-direction burr height

Fig.7 y-direction burr height

Fig.8 Comparison of surface burr heights (n=8000r/min, f=400mm/min, ae=2.5mm)

Fig.9 Micro-edge milling and integral edge milling

Fig.10 Force analysis

Fig.11 Equivalent chip and equivalent chip thickness

Table 3 Effects of parameters on tangential specific cutting energy and y-direction burr height for different tools

刀具	f=400 mm/min, a_e=1.5 mm	n=8000 r/min, a_e=1.5 mm	n=8000 r/min, f=400 mm/min
压米铣刀
涂层铣刀
复合铣刀
PCD铣刀

Fig.12 Maximum milling temperature of the four tools

Fig.13 Infrared image of milling temperature

Fig.14 Machined surface roughness Sa

Fig.15 Effects of milling temperature on fiber fracture[25]

Fig.16 Machined surface topography

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