Tool Wear In High Speed Milling Of Carbon Fiber Reinforced Plastics

Carbon fiber reinforced plastics(CFRP)with light weight,high strength,good mechanical properties,high temperature resistant,anticorrosion characteristics are widely used in aerospace,military,automotive,construction and other industries.But during high speed milling of CFRP,due to the anisotropy,heterogeneity and poor thermal conductivity properties of the material,it is easy to produce layered surface,burrs and other defects.And it cause severe wear to tool,which restricts the application of high speed cutting technology.Therefore,it is necessary to study the tool wear during high speed milling of CFRP.It can also promote the popularization and application of high speed cutting technology,which has important theoretical and practical significance.This paper mainly adopts the method of experimental research,using the integral cemented carbide and its coating(TiCN?TiAIN)cutters to further research the process parameters,tool wear mechanism and wear prediction in high speed milling of CFRP.The results show that tool wear has a significant effect on cutting force.The radial force and tangential force rise as the increase of the flank wear and rake wear,respectively.And the radial force increases by a big margin.Then,cutting depth has the highest significant impact on cutting force,followed by the feed per tooth and spindle speed.Radial force rises with the increase of spindle speed,feed per tooth and cutting depth.Tangential force rises as the increase of feed per tooth and cutting depth,but declines with the spindle speed.As the increase of rake angle or flake angle,radial force and tangential force firstly declines and then rises.On the other hand,radial force and tangential force of three different tools rise as the increase of cutting length and the increase rate of uncoated tool is the largest,followed by TiCN coated and TiAIN coated.On the tool wear mechanism and failure form,the flank face of the uncoated tool mainly suffers abrasive wear,adhesive wear and oxidation wear,while matrix flaking and micro-chipping are observed to be the main failure form.TiCN coated tool also suffers abrasive wear,adhesive wear and slight oxidation wear,and the form of failure is same as the uncoated tool.However,TiAlN coated tool mainly suffers abrasive wear and adhesive wear while the main failure form is flaking.In general,TiAlN coated tool obtaining the smallest flank wear,cutting force and burrs expansion,is more suitable for processing carbon fiber reinforced plastics.At the respect of tool wear prediction based on BP neural network,the error of the predicted compared to the actual is mostly less than 5%,and only a handful is more than 5%.It shows that the model has good ability of prediction.So,it can be applied to the actual production process,and has a guiding role in judging the state of the tool.