Experimental Study On Milling Glass Fiber/carbon Fiber Aramid Paper Honeycomb Panel

Fiber composite honeycomb panel has been one of the hottest composites in present aerospace and military fields, which having excellent properties such as lightweight, high specific strength and stiffness, heat insulation and shock-absorbing, resistance impact, etc. It is regarded as one of the best materials with high strength and lightweight, and promotes the development of lighter mechanical product. Nowadays, it has been gradually expanded to train, ship, building and other fields nowadays. But the materials’ machining capability is poor, is a typical difficult-to-machine materials. With the widely application of it, the contradiction between difficult-to-machine and use requirement increasingly.In the paper, based on the experiment of milling glass fiber/carbon fiber aramid paper honeycomb panel, milling cutter optimization selection, milling dosage optimizing, tool wear and the machining quality of honeycomb panel are studied. The main work and conclusions are as follows:(1) The paper studies the cutting performances of different edge shape milling cutter by the experiment of milling cutter optimization selection. The results show that: compared with general edge cemented carbide milling cutter, the wear of CVD diamond film coated milling cutter is smaller, and the surface quality of honeycomb panel is better. However, compared with herringbone edge CVD diamond film coated milling cutter, the machining quality of diamond edge CVD diamond film coated milling cutter is better.(2) The paper studies the influences of milling dosage on tool wear and machining quality of honeycomb panel, and analyzes the tool wear mechanism and the effect of fiber orientation on machining quality of glass fiber by single factor experiment. Research shows that: the tool flank wear increases with the raising of spindle speed, milling width or decreasing of feed rate; the length of glass fiber burr increases with the raising of milling width or decreasing of feed rate; The machining deformation of 0° glass fiber contain interlamination separation, bending and shearing fracture. The machining deformation of 90° glass fiber is shear fracture. The wear mechanisms of cemented carbide tools are abrasive wear. The wear mechanisms of CVD diamond coated tools are abrasive wear and coating peeling.(3) The optimal analysis of milling dosage is taken by the orthogonal experimental analysis. Base on the result of orthogonal experiment, the mathematical model of tool wear is built. The results show that: milling width has a significant effect on the flank wear of coated or uncoated tool and the length of glass fiber burr. Feed rate has a great impact on the flank wear of cemented carbide tools. When the spindle speed is 5500r/min, the feed rate is 250mm/min, the milling width is 1mm, the wear mass loss of flank face is least, and the cutting quality of specimens are good. The tool wear model of high accuracy is obtained by regression, and can accurately reflect the relations between tool wear and milling dosage. It provides a reference basis for making actual process parameter.(4) Based on the tool life experiment, the lifetime of cemented carbide tools and diamond CVD diamond film coated tool is studied. From tool wear of view, the lifetime of coated tool is about 5 times than general cemented carbide milling cutter. From the cutting quality of view, the lifetime of coated milling cutter is about 14 times than general cemented carbide milling cutter.