Ultrasonic Vibration-aided Milling And Drilling Of CFRP Materials

Carbon fiber-reinforced composite material is a popular advanced composite material in the new time.They have a wide range of applications from aerospace down to sports equipment and many other fields,but its high-efficiency and high-quality processing cannot meet people’s demand brought by the rapid development of technology..Therefore,this article combines the idea of replacing a component on a broadcasting 787 rudder proposed by an aerospace company with a composite material,taking carbon fiber composite materials as the research object,and performing edge trimming and drilling experiments to provide parameter range of processing composite material trimming and drilling.Through single-factor and orthogonal tests of cutting and drilling,cutting forces and surface roughness values were used as research objectives.The XKA715 A CNC milling machine and ultrasonic vibration-assisted cutting unit were used to drill and cut carbon fiber composites.Taking the spindle speed,feed per tooth,and ultrasonic power as factors,two sets of orthogonal tests with three factors and three levels are set up,one of orthogonal tests for milling and the other for drilling.And two group of single-factor experiments are set.14 sets for milling,14 sets for drilling.The influence of the spindle speed,feed per tooth,and ultrasonic power on cutting force and surface roughness is as follows:(1)As result of milling,the spindle speed has the greatest influence on the X direction milling force,and the amount of feed per tooth has the greatest influence on the Y direction milling force.The trend of the influence of milling force and surface roughness in both directions is the same.It increases with the increase of the spindle speed and increases with the increase of the feed per tooth,and the force at the ultrasonic power of 50% is the smallest.The surface roughness value is the smallest.For drilling experiments,the increase of spindle speed makes the drilling force decrease,the surface roughness value decreases,the feed per tooth increases,the drilling force and the surface roughness increase,and the ultrasonic power is selected from 50% to 60%.Both force and roughness values are minimal.(2)The influence of each parameter on the cutting force in the Y direction in themilling experiment is: spindle speed> feed per tooth> ultrasonic frequency;the influence of milling force in X direction is: feed per tooth> spindle speed> ultrasonic frequency.The comprehensive effect of the parameters of the milling test on the surface roughness value is: spindle speed> feed per tooth> ultrasonic frequency.The influence of each parameter in the drilling experiment on the drilling and hole wall roughness of carbon fiber composite materials is: spindle speed> feed per tooth>ultrasonic frequency.