Experimental Research On C/E Composites Grinding Instead Of Milling

Carbon/epoxy (C/E) composites are advanced composite materials, which have a number of advantages, such as high strength, high modulus, low coefficient of thermal expansion and good vibration absorption, etc. C/E composites are being increasingly widely used in development and production of new products in aerospace and defense industry, such as the aircraft wing, large launch vehicle cabin, spacecraft cabin and missile launchers, etc. C/E composites have characteristics of high hardness, high brittleness, lower inter-laminar strength, anisotropy and heterogeneity, which are typical materials is difficult to machine. After the component molding of C/E composites, in order to meet functional requirements, it is need for appropriate secondary processing in C/E composites to meet functional requirements, in particular, the need for a large number of machining blind-slot, machining the windows and polishing flange face and so on.This paper combines the National Natural Science Foundation of China (50875034) and High Technology Research and Development Program (863 Program,2009AA044304), the C/E composites as the research object and processing blind-slot as an example, carrying out exploratory studies about secondary processing of C/E composites. The main research work is as follows:(1) For C/E composites properties, the paper tries to use cemented carbide mill cutter to carry out blind-slot milling test for multi-directional C/E composites, analyzing the impact of different processing parameters on surface quality of blind-slot, analyzing surface morphology, wearing mechanism and machining performance of tool wear in the process of machining, and getting the conclusions of blind-slot machining quality in general and lower tool life. This paper uses the milling of uni-directional C/E composites to research the impact of carbon fiber orientation on surface quality, further analyzing milling defects mechanism of multi-directional C/E composites.(2)For the shortcoming of surface quality and low tool life in the process of milling multi-directional C/E composites with cemented carbide mill cutter, this paper combines the characteristics of C/E composites, and proposes the technology of Grinding instead of Milling to achieve to machining blind-slot on multi-directional C/E composites. Multi-directional C/E composites is cascading laying adhesive structure, so only does this paper flight-cutting test on single-beam carbon fiber (single-layer fiber) and multi-layer carbon fiber plate, which can help us to understand and master failure mechanism of the forces in the machining process. For this, this paper carries out flight-cutting test on unidirectional multi-layer C/E composites and single-beam C/E composites, and thus researching on mechanism of removal material, bottom roughness of blind-slot and the mechanism of burrs in the process of grinding material.(3) Electroplated diamond tools for grinding process as the research object, analyzes grinding performance of uni-directional C/E composites in different carbon fiber orientation, and explores cutting mechanism in different carbon fiber orientation, thus analyzes feasibility of grinding multi-directional C/E composites. Multi-directional C/E composites have a high value for industrial applications, so cemented carbide mill cutter as the research object, analyzes surface quality, bottom roughness of blind-slot, grinding force and tool wear in the process of grinding with electroplated diamond tool, and achieves empirical formula of maximum grinding force for electroplated diamond tool, thus gets the conclusion that Grinding instead of Milling can effectively improves the surface quality blind-slot.