Experimental Research On Milling Carbon Fiber Reinforced Plastics With Staggered PCD End Mill

Carbon fiber reinforced plastics(CFRP) has been widely used in aerospace, defense and energy industry because of its excellent performances such as high specific strength and high specific modulus. However, due to the fact that the structure of CFRP is lamellar, heterogeneous, anisotropy, machining will cause serious damages like delamination, burrs, tear and so on, which leads to complex surface quality and serious tool wear. To improve the processing quality of CFRP, a staggered PCD end mill is designed and manufactured. Experimental research on the milling force, surface quality and tool wear of staggered PCD end mill are carried out, and the main contents are as follows.Firstly, according to the problems of CFRP processing defects and rapid tool wear, the influence mechanism of tool structure on CFRP milling machining defects is analyzed in this paper. The staggered PCD end mill is designed and the finite element analysis is done. in order to produce the staggered PCD end mill, technology of welding and grinding is studied as well.Secondly, the influence of milling parameters and cutting angle of fiber on the milling force is studied combining with the CFRP milling experiment. By the range analysis of the milling force, the empirical prediction model of the milling force is established, and the model is verified by test.Thirdly, the research of the CFRP surface quality processed by the staggered PCD end mills is conducted to obtain the influence mechanism of milling parameters on the surface roughness. By cutting and slotting milling experiments of unidirectional CFRP materials, the surface topography of four kinds of fiber cutting angle conditions is studied and the influence mechanism of CFRP the cutting angle on the surface defects is obtained.Finally, the PCD tool wear patterns and mechanism are analyzed while milling CFRP and the effects of tool wear on burr defects and surface roughness are studied as well. In view of the tool wear and machined surface quality, the machining performance of three kinds of PCD end mill such as staggered, double pressure and spur gear is comparatively analyzed.This paper not only provides the design and manufacturing method of the staggered PCD end mill for CFRP, but also analyzes the milling performance of staggered PCD end mill, so it is of great significance to the promotion and application of staggered PCD end mills.