Top > IJAT > Cutting Characteristics in End-Milling of CFRP with Diamond-Co ...

single-au.php

IJAT Vol.10 No.3 pp. 356-363
doi: 10.20965/ijat.2016.p0356
(2016)

Paper:

Views over last 60 days: 1,141

Cutting Characteristics in End-Milling of CFRP with Diamond-Coated Herringbone Tool

Tetsuya Tashiro*,†, Junsuke Fujiwara**, and Nao Asahi***

*Department of Mechanical Systems, Osaka Prefecture University College of Technology
26-12 Saiwai-cho, Neyagawa, Osaka 572-8572, Japan

†Corresponding author, E-mail: tas@osaka-pct.ac.jp

**YMP-Mundus Corporation, Osaka, Japan

***AVC Networks Company Panasonic Corporation, Osaka, Japan

Received:
October 1, 2015
Accepted:
April 11, 2016
Published:
May 2, 2016
Creative Commons License
Keywords:
end-milling, CFRP, herringbone shape tool, diamond coated, tool wear
Abstract
Because carbon fiber-reinforced plastics (CFRP) is used for various parts, it requires cutting. However, CFRP is well known to be difficult to cut. In this study, two types of tools were used to trim CFRP. At first, a conventional shaped tool was used. The cutting forces on the CFRP were measured and the influence of the fiber orientation relative to the cutting direction was investigated. Next, a herringbone-shaped tool was used and compared with the conventional end-mill. Specifically, cutting forces, burr formation, and surface roughness were measured to characterize the effect of this tool position. The characteristics of a diamond-coated tool were also investigated. The effectiveness of the diamond-coated herringbone tool was clarified. The main results obtained are as follows: 1) Cutting forces change by changing the tool axis position of the herringbone tool; the tool axis position is an important cutting condition. 2) By choosing the appropriate tool axis position, no uncut carbon fiber remains on the cut surface of the CFRP with the herringbone tool. 3) The burr formed under down-cut milling is smaller than that of up-cut milling at the cut end of CFRP by using the herringbone tool. 4) Small debonding of the diamond coating occurs on the cutting edge, but the wear value is very small, and the shape of the cutting edge is maintained despite small debonding of the diamond coating. 5) Diamond particles on the cutting edge do not work as those for grinding do. Sharp cutting edges with large rake angles and relief angles can cut the carbon fibers cleanly.
Cite this article as:
T. Tashiro, J. Fujiwara, and N. Asahi, “Cutting Characteristics in End-Milling of CFRP with Diamond-Coated Herringbone Tool,” Int. J. Automation Technol., Vol.10 No.3, pp. 356-363, 2016.
Data files:
References
  1. [1] E. Brinksmeier, S. Fangmann, and R. Rentsch, “ Drilling of composites and resulting surface integrity,” CIRP Annals Manufacturing Technology, Vol.60, pp. 57-60, 2011.
  2. [2] K. Akai, Y. Kageyama, K, Sato, N. Nishino, and K. Kageyama, “AHP Analysis of the Preference of Engineers for Suitable CFRP for Automovile Parts,” Int. J. of Automation Technology, Vol.9, pp. 222-234, 2015.
  3. [3] E. Uhlmann, F.Sammler, S. Richarz, F. Heitmuller, and M. Bilz, “Machining of Carbon Fibre Reinforced Plastics,” Procedia CIRP, Vol.24, pp. 19-24, 2014.
  4. [4] W. Hintze, D. Hartmann, and C. Schutte, “Occurence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs) – An experimental study,” Composites Science and Technology, Vol.71, pp. 1030-1037, 2011.
  5. [5] J. Fujiwara, R. Nagaura, and T. Tashiro, “Drilling of CFRP/Ti6Al4V Stack Board,” Int. J. of Automation Technology, Vol.7, pp. 426-432, 2013.
  6. [6] O. Pecat, R. Rentsch, and E. Brinksmeier, “Influence of milling process parameters on the surface integrity of CFRP,” Procedia CIRP, Vol.1, pp. 466-470, 2012.
  7. [7] S. Fukami, N. Morita, S. Yamada, and N. Takano, “ Study on high efficiency and highly accurate CFRP processing method,” J. of the Japan Society for Abrasive Technology, Vol.56, pp. 545-551, 2012.
  8. [8] Hanasaki, J. Fujiwara, and M. Nomura, “Tool Wear Mechanism in Cutting of CFRP,” J. of The Japanese Society of Mechanical Engineering (C), Vol.60, pp. 297-302, 1994.
  9. [9] S. Hanasaki, J. Fujiwara, T. Kawai, M. Nomura, and T. Miyamoto, “Study on tool wear mechanism of CFRP cutting II,” J. of The Japanese Society of Mechanical Engineering (C), Vol.71, pp. 719-724, 2005.
  10. [10] A. Koplev, A. Lystrup, and T. Vorm, “The cutting process, chips, and cutting forces in machining CFRP,” Composites, Vol.14, pp. 371-376, 1983.
  11. [11] T. Higaino, T. Aoyama, and H. Ogawa, “Study on End Milling of CFRP with Coolant and Cemented Carbide End Mill,” J. of the Japan Society for Precision Engineering, Vol.81, pp. 333-338, 2015.
  12. [12] T. Kaneeda and M. Takahashi, “CFRP Cutting Mechanism (1st Report) – Surface Generation Mechanism at Very Low Cutting Speeds –,” J. of the Japan Society for Precision Engineering, Vol.55, pp. 1456-1461, 1989.
  13. [13] T. Kaneeda and M. Takahashi, “CFRP Cutting Mechanism (2nd Report) – Analysis of Depth of Reluctant Uncut and Deformed Part –,” Vol.56, pp. 1058-1063, 1990.
  14. [14] S. Tamura and T. Matsumura, “Cutting Force Prediction in Drilling of Unidirectional Carbon Fiber Reinforced Plastics,” Int. J. of Automation Technology, Vol.9, pp. 59-66, 2015.
  15. [15] M. Henerichs, T. Voβ, F. Kuster and K. Wegener, “Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces,” CIRP J. of Manufacturing Science and Technology, Vol.297, 2014.
  16. [16] M. Hagino and T. Inoue, “Effect of Carbon Fiber Orientation and Helix Angle on CFRP Cuttiing Characteristics by End-Milling,” Int. J. of Automation Technology, Vol.7, pp. 292-299, 2013.
  17. [17] S. Maegawa, Y. Morikawa, S. Hayakawa, F. Itoigawa, and T. Nakamura, “Effect of Fiber Orientation Direction on Tool-Wear Processes in Down-Milling of Carbon Fiber-Reinforced Plastic Laminates,” Int. J. of Automation Technology, Vol.9, pp. 356-364, 2015.
  18. [18] T. Yashiro, T. Ogawa, and H. Sasahara, “Temperature measurement of cutting tool and machined surface layer in milling of CFRP,” Int. J. of Machine Tool & Manufacture, Vol.70, pp. 63-69, 2013.
  19. [19] K. Ono, S. Kawamura, M. Kitano and T. Simamune, “Cutting Theory,” Gendaikougakusya, 1979.
  20. [20] T. Tashiro, J. Fujiwara, S. Hanasaki, and S. Fujiwara, “Formation mechanism of ground surface of CFRP,” J. of the Japan Society for Abrasive Technology, Vol.49, pp. 99-104, 2005.

Creative Commons License  This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Apr. 05, 2024