Experimental determination of tool wear in routing and trimming of CFRP composites

Peker, Zühal
In order to fulfill growing demand for lighter aircraft, Carbon fiber reinforced polymers (CFRP) have been developed, which differ from metals with regards to their machinability characteristics. The main problem in machining process is the damage caused by delamination of CFRP materials which need to be both cut and shorn of fibers at the same time, since they are remarkably abrasive in nature. This research aims at accessing the most appropriate cutting condition with less tool wear in routing and trimming operations for CFRP composite material. In the current study, a diamond coated interlocked tool with 12 cutting edges and 10 millimeter diameter is used for routing and trimming CFRP composite materials which has unidirectional carbon fibers. The experiments are carried out by altering the spindle speed and feed per tooth value while keeping the radial depth of cut constant. The experiments were done using 3-axis vertical machining center. At the beginning, 16 feed per tooth values were chosen in 5000 rpm to perform the machining test. The cutting forces were obtained from rotary type dynamometer during cutting operations. Tool wear and delamination measurements were done using an optical microscope. From the test results, 3 feed per tooth values were observed at 5000 rpm in terms of tool wear and delamination. The best cutting conditions for high surface quality are obtained for high spindle speeds of 5000 rpm and low feed per tooth values of about 0.02, 0.03 and 0.04 mm/ tooth.
Citation Formats
Z. Peker, “Experimental determination of tool wear in routing and trimming of CFRP composites,” M.S. - Master of Science, Middle East Technical University, 2015.