Damage Mechanism And Countermeasures Of Helical Milling In CFRP/Titanium Alloy Laminated Components

Carbon fiber reinforced plastics(CFRP)and titanium alloy both have a series of advantages such as the light quality,high specific strength,fatigue resistance and corrosion resistance etc.In the field of aerospace has made a lot of applications.Firstly,to research the influence of the drilling parameters on drilling force and the vibration characteristics during drilling process of CFRP/Ti stacks.It uses the method of orthogonal experiment for laminated material to the integrated drilling experiment.Through the analysis of drilling force to study the vibration characteristics in the process of drilling.The results showed that the torque and drilling force decreased with the spindle speed increases,increased along with the increase of feed speed,and the influence of feed rate on the drilling force stronger than spindle speed to its influence.During processing in higher spindle speed,low feed rate will guarantee the quality of hole.During the processing of CFRP/Ti stacks,there are sharp cutting vibration phenomenon when the two material contact surface is processed.Secondly,according to the wear of cutting tool in helical milling and traditional drilling.In this paper,the experiment carry out on CFRP / Ti laminated materials with helical milling and traditional drilling test.The results show that the cutting force of the helical milling is obviously smaller than drilling hole.During the machining process,the cutting force of the helical milling is more gentle than the cutting force of the drilling.The tool of the helical milling is more wear-resistant than the drilling tool,and the number of machining holes is more.Then,to study the different blade number milling cutter helical milling hole situation.Under the same cutting parameters,the cutting force,tool flank wear length,CFRP inlet quality and Ti export quality of the two kinds of milling cutter are measured.The results show that the axial thrust and radial forces produced by the 2-edge cutter are lower than the axial thrust and radial forces generated by the 4-edge cutter.In terms of the quality of imports and exports,the 2-blade cutter suppresses the flash phenomenon at the Ti outlet.The 4-blade cutter suppresses the entrance burrs of CFRP.Finally,in order to study the situation of spiral milling of different milling cutters,aiming at different milling tools,the research on the hole milling of laminated materials by helical milling was carried out.The cutting force and the aperture of laminated materials were tested.The results show that during radial milling of CFRP / Ti laminates,the tool radial forceand axial force are related to the tool shape.For helical milling of CFRP / Ti laminates,the ball-end mill is more suited to hole making than flat-bottom milling.When using a ball end mill,the size of the carbon fiber composite and the titanium alloy decreases with the increase of the fillet radius.Helical milling CFRP / Ti laminated materials,cutting force and aperture from the comprehensive consideration,the choice of rounded corners radius of 0.5mm round milling cutter for spiral milling hole machining will be better.