Experimental Study on Milling CFRP with Staggered PCD Cutter
Experimental Study on Milling CFRP with Staggered PCD Cutter
复制标题
交错式PCD刀具铣削CFRP的实验研究
DOI：
10.3390/app7090934
复制
发表时间：
2017-09-01
影响因子：
2.7
通讯作者：
Liu, Xianli
中科院分区：
文献类型：
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作者：
Chen, Tao;Wang, Daoyuan;Liu, Xianli
碳纤维增强塑料（CFRP）具有高比强度和高比模量等良好的物理性能。然而，在CFRP加工过程中经常出现切削分层、撕裂和毛刺等现象，导致加工表面质量不可控，刀具磨损严重。采用交错铣刀对CFRP进行铣削加工，研究刃口半径对刀具磨损的影响；研究了尖端磨损半径对铣削力和表面质量的影响，分析了磨损状态下三维表面形貌和表面缺陷的形成机理。实验结果表明，交错PCD刀具的磨损主要集中在刃口区域。随着铣削长度的增加，在磨粒磨损机制的作用下，刃口半径逐渐变大，刃口磨损不明显。随着刀具磨损强度的增大，铣削力逐渐增大，CFRP的加工表面质量明显恶化，即出现裸纤维断裂、沟槽、孔洞等缺陷，工件表面逐渐产生毛刺。最后，通过切削性能对比分析，发现交错PCD刀具比直齿刀具具有更好的耐磨性和抑制毛刺的性能。这一发现可为提高碳纤维复合材料的加工质量提供理论和技术支持。
Carbon fiber reinforced plastics (CFRP) have good physical properties, such as high specific strength and high specific modulus. However, cutting delamination, tearing and burr, etc. often occur in the machining process of CFRP, which results in the uncontrollability of machining surface quality and serious tool wear. In this paper, milling of CFRP with a staggered cutter was carried out, the cutting-edge radius was investigated in order to characterize the tool wear; the effect of the cutting-edge wear radius on the milling force and surface quality was found, and the formation mechanisms of the 3D surface topography and surface defects were analyzed under the wear state. Experimental results showed that the wear of the staggered PCD cutter was mainly concentrated in the cutting-edge area. With the increase in milling length, the radius of cutting edge gradually became largeer under the action of abrasive wear mechanism, and the flank wear was not obvious. With the intension of tool wear, milling force gradually increased and the machining surface quality of the CFRP deteriorated distinctly, i.e., defects such as bare fiber fracture, groove and hole appeared, and burrs were gradually generated on the workpiece surface. Finally, through a comparative analysis of cutting performance, it was found that the staggered PCD cutter possessed better performance for wear resistance and burr suppression than the straight-teeth cutter. This finding can provide theoretical and technical support for improving the machining quality of carbon fiber composite materials.