Hostname: page-component-586b7cd67f-2brh9 Total loading time: 0 Render date: 2024-11-24T18:54:39.994Z Has data issue: false hasContentIssue false
  • English
  • Français

Study on wear mechanism of solid carbide cutting tool in milling CFRP

Published online by Cambridge University Press:  29 February 2016

Nor Khairusshima Muhamad Khairussaleh ,
Che Hassan Che Haron  and
Jaharah A. Ghani
Nor Khairusshima Muhamad Khairussaleh*
Affiliation:
Department of Manufacturing and Materials Engineering, Faculty of Engineering, International Islamic University Malaysia, 53100 Gombak, Selangor, Malaysia
Che Hassan Che Haron
Affiliation:
Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, University Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
Jaharah A. Ghani
Affiliation:
Department of Mechanical and Material Engineering, Faculty of Engineering and Built Environment, University Kebangsaan Malaysia, 43600 Bangi, Selangor, Malaysia
*
a)Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

Carbon fiber reinforced plastic (CFRP) is an expensive composite which has become valuable material as the demand for this composite increased in the industries. It is suitable to be used in automotive, aerospace, and aircraft because of its properties which is stronger than steel and also stiffer than titanium while retaining its lighter weight. However machining of CFRP is a mess to machinist due to its nature which is abrasive. The paper presents the wear mechanism on solid carbide cutting tool during milling CFRP. The wear mechanism is observed under dry and chilled air machining. The machining parameters tested were at cutting speed of 200 m/min with constant feed rate and depth of cut. For both dry and chilled air machining, it is observed that carbide cutting tool experienced abrasive wear which has been influenced by abrasive powdering chips and fibers during milling CFRP. Under microscope and scanning electron microscope, the abrasive wear is represented by shiny and polish area on the cutting tool respectively. This abrasive wear is observed higher under dry machining compared to the chilled air machining which was due to the heat generated during machining. Thus, chilled air has a potential of improving machinability of CFRP by using solid carbide cutting tool.

Keywords

carbon fiber reinforced plasticwear mechanismcarbide cutting toolmilling chilled air machining
Type
Article
Information
Journal of Materials Research , Volume 31 , Issue 13: Focus Issue: Advances and Challenges in Carbon-based Tribomaterials , 14 July 2016 , pp. 1893 - 1899
Check for updates
Copyright
Copyright © Materials Research Society 2016 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Cong, W.L., Pei, Z.J., Deines, T.W., Liu, D.F., and Treadwell, C.: Rotary ultrasonic machining of CFRP/Ti stacks using variable feedrate. Composites, Part B 52, 303–310 (2013).CrossRefGoogle Scholar
Krishnaraj, V., Prabukarthi, A., Ramanathan, A., Elanghovan, N., Senthil Kumar, M., Zitoune, R., and Davim, J.P.: Optimization of machining parameters at high speed drilling of carbon fiber reinforced plastic (CFRP) laminates. Composites, Part B 43(4), 1791–1799 (2012).CrossRefGoogle Scholar
Klotz, S., Gerstenmeyer, M., Zanger, F., and Schulze, V.: Influence of clamping systems during drilling carbon fiber reinforced plastics. Procedia CIRP 13, 208–213 (2014).Google Scholar
Makhdum, F., Phadnis, V.A., Roy, A.S., and Silberschmidt, V.V.: Effect of ultrasonically-assisted drilling on carbon-fibre-reinforced plastics. J. Sound Vibration 333(23), 5939–5952 (2014).Google Scholar
Cong, W.L., Pei, Z.J., Deines, T.W., Liu, D.F., and Treadwell, C.: Rotary ultrasonic machining of CFRP: A mechanistic predictive model for cutting force. Ultrasonics 54(2), 663–675 (2014).Google Scholar
Hintze, W., Hartmann, D., and Schütte, C.: Occurrence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs)—An experimental study. Compos. Sci. Technol. 71(15), 1719–1726 (2011).Google Scholar
Uhlmann, E., Sammler, F., Richarz, S., Heitmüller, F., and Bilz, M.: Machining of carbon fibre reinforced plastics. Procedia CIRP 24, 19–24 (2014).Google Scholar
Henerichs, M., Voß, R., Kuster, F., and Wegener, K.: Machining of carbon fiber reinforced plastics: Influence of tool geometry and fiber orientation on the machining forces. CIRP J. Manuf. Sci. Technol. 9, 136–145 (2015).CrossRefGoogle Scholar
Tsao, C.C. and Chiu, Y.C.: Evaluation of drilling parameters on thrust force in drilling carbon fiber reinforced plastic (CFRP) composite laminates using compound core-special drills. Int. J. Mach. Tools Manuf. 51(9), 740–744 (2011).Google Scholar
Brinksmeier, E., Fangmann, S., and Rentsch, R.: Drilling of composites and resulting surface integrity. CIRP Ann. - Manuf. Technol. 60(1), 57–60 (2011).Google Scholar
Karpat, Y., Değer, B., and Bahtiyar, O.: Drilling thick fabric woven CFRP laminates with double point angle drills. J. Mater. Process. Technol. 212(10), 2117–2127 (2012).Google Scholar
Park, K-H., Beal, A., Kim, D., Kwon, P., and Lantrip, J.: Tool wear in drilling of composite/titanium stacks using carbide and polycrystalline diamond tools. Wear 271(11–12), 2826–2835 (2011).Google Scholar
Voß, R., Henerichs, M., Kuster, F., and Wegener, K.: Chip root analysis after machining carbon fiber reinforced plastics (CFRP) at different fiber orientations. Procedia CIRP 14, 217–222 (2014).CrossRefGoogle Scholar
Palanikumar, K. and Paulo Davim, J.: Mathematical model to predict tool wear on the machining of glass fibre reinforced plastic composites. Mater. Des. 28(7), 2008–2014 (2007).Google Scholar
Liu, J., Chen, G., Ji, C., Qin, X., Li, H., and Ren, C.: An investigation of workpiece temperature variation of helical milling for carbon fiber reinforced plastics (CFRP). Int. J. Mach. Tools Manuf. 86, 89–103 (2014).Google Scholar
Kim, S.W., Lee, D.W., Kang, M.C., and Kim, J.S.: Evaluation of machinability by cutting environments in high-speed milling of difficult-to-cut materials. J. Mater. Process. Technol. 111(1–3), 256–260 (2001).CrossRefGoogle Scholar
Shokrani, A., Dhokia, V., and Newman, S.T.: Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. Int. J. Mach. Tools Manuf. 57, 83–101 (2012).Google Scholar
Jozić, S., Bajić, D., and Celent, L.: Application of compressed cold air cooling: Achieving multiple performance characteristics in end milling process. J. Cleaner Prod. 100, 325–332 (2015).CrossRefGoogle Scholar
Liu, J. and Kevin Chou, Y.: On temperatures and tool wear in machining hypereutectic Al–Si alloys with vortex-tube cooling. Int. J. Mach. Tools Manuf. 47(3–4), 635–645 (2007).Google Scholar
Sun, S., Brandt, M., Palanisamy, S., and Dargusch, M.S.: Effect of cryogenic compressed air on the evolution of cutting force and tool wear during machining of Ti–6Al–4V alloy. J. Mater. Process. Technol. 221, 243–254 (2015).Google Scholar
Nor Khairusshima, M.K., Che Hassan, C.H., Jaharah, A.G., Amin, A.K.M., and Md Idriss, A.N.: Effect of chilled air on tool wear and workpiece quality during milling of carbon fibre-reinforced plastic. Wear 302(1–2), 1113–1123 (2013).Google Scholar
Rawat, S. and Attia, H.: Wear mechanisms and tool life management of WC–Co drills during dry high speed drilling of woven carbon fibre composites. Wear 267(5–8), 1022–1030 (2009).CrossRefGoogle Scholar
Iliescu, D., Gehin, D., Gutierrez, M.E., and Girot, F.: Modeling and tool wear in drilling of CFRP. Int. J. Mach. Tools Manuf. 50(2), 204–213 (2010).Google Scholar
Wang, X., Kwon, P.Y., Sturtevant, C., Kim, D., and Lantrip, J.: Tool wear of coated drills in drilling CFRP. J. Manuf. Processes 15(1), 127–135 (2013).Google Scholar
Warren, A., Nylund, A., and Olefjord, I.: Oxidation of tungsten and tungsten carbide in dry and humid atmospheres. Int. J. Refract. Met. Hard Mater. 14(5–6), 345–353 (1996).Google Scholar
Palanikumar, K. and Davim, J.P.: Assessment of some factors influencing tool wear on the machining of glass fibre-reinforced plastics by coated cemented carbide tools. J. Mater. Process. Technol. 209(1), 511–519 (2009).Google Scholar
Campos Rubio, J.C., José da Silva, L., Wanderson de Oliveira, W., Hallak Panzera, T., Sergio Luiz Moni Ribeiro, T., and Paulo Davim, J.: Investigations on the drilling process of unreinforced and reinforced polyamides using Taguchi method. Composites, Part B 55, 338–344 (2013).Google Scholar
Karnik, S.R., Gaitonde, V.N., Campos Rubio, J., Esteves Correia, A., Abrão, A.M., and Paulo Davim, J.: Delamination analysis in high speed drilling of carbon fiber reinforced plastics (CFRP) using artificial neural network model. Mater. Des. 29(9), 1768–1776 (2008).CrossRefGoogle Scholar
Gisip, J., Gazo, R., and Stewart, H.A.: Effects of cryogenic treatment and refrigerated air on tool wear when machining medium density fiberboard. J. Mater. Process. Technol. 209(11), 5117–5122 (2009).Google Scholar