The Milling Performance Study Of Carbon Fiber Reinforced Resin Matrix Composites

Carbon fiber reinforced resin matrix composites with light weight,high strength,high temperature resistant,anticorrosion characteristics are widely used as structural materials and high temperature resistant material.From the previous focus on aerospace and military fields,the composite gradually expand to industrial applications.But they are the typical difficult-to-machine materials.The heterogeneity,anisotropy and large brittleness make it prone to surface defects such as delamination,tearing and uneven in machining process.And its high hardness and poor heat conductivity characteristics lead to serious tool wear.High speed cutting with the advantages of high efficiency,low cost,and low energy consumption is an advanced manufacturing technology.Its main application fields is to solve the machining of difficult-to-machine materials.Therefore,for providing theoretical evidence of high speed milling carbon fiber composite materials and selection of cutting tool,it is necessary to study the performance of milling of carbon fiber composite materials.This paper mainly adopts the method of experimental research,using the integral cemented carbide and its coating(AlCrN,TiAIN)cutters to research the cutting force,surface roughness and tool wear in high speed milling carbon fiber composite material.The results show that the milling force component is cyclical fluctuation as sine curve;The cutting force of Coated tools is less than uncoated tools,and it can obtain better surface roughness.Under different tools,the influence of cutting parameters on cutting force and surface roughness are almost the same.Cutting force and surface roughness increase with cutting depth and feed per tooth.Overall,cutting force increases with cutting speed,but the trend of increase is slowly.However,the surface roughness decrease with the increase of cutting speed at first and then increase.The results of cutting force spectrum analysis of TiAIN tools in the experiment show that in general,the amplitude of spindle unbalanced force and cutting force decrease with the increase of cutting speed,but when the cutting speed is up to 450 m/min,the amplitude of Y-axis spindle unbalanced force sharply increases.Spindle unbalance force and main frequency of cutting force frequency response function increased linearly with the increase of cutting speed;the tooth passing frequency is the second harmonic frequency for the spindle frequency.Feed per tooth has the most dominant role in influencing the feed force Fx,followed by effect of cutting depth and the effect of cutting speed is negligible.Feed per tooth has the most dominant role in influencing the tangential force Fy,followed by cutting speed and the effect of cutting depth is negligible.Feed per tooth has mostly influenced the surface roughness,followed by cutting speed and the effect of cutting depth has been found to be negligible.Tool wear is mainly influenced by feed per tooth and cutting speed,and the effect of cutting depth of is not big.Tool wear increases with cutting speed and feed per tooth.Finally,I established the model of cutting force Fx,Fy,surface roughness and tool wear,respectively.At last,the tool wear mechanism of three different materials was further studied by scanning electron microscopy(SEM)and energy spectrum analysis.There was no typical crater wear of metal cutting on rake face.The rake face appeared slight chip adhesion,but the adhesion of uncoated cemented carbide tool is unusually severe,and appear the phenomenon of collapse edge.Wear areas are showing wear and tear like polished band and there has slight groove on cutting direction.The coating flaking is obvious on flank face of coated tool.The wear mechanism of three different tools are mainly abrasive wear and adhesion wear.