Machining Performance and Material Removal Mechanism of High-speed Milling of CFRP with Variable Angle under Minimal Quantity Lubrication

doi:10.3969/j.issn.1004-132X.2023.21.012

Abstract

Abstract: High-speed cutting performance of CFRP was investigated by a specially designed regular dodecagonal cutting trajectory method. Factors such as cooling and lubrication conditions， fiber cutting angles， cutting speed， and down/up milling were analyzed for their influence mechanism on the cutting performance of CFRP. Material removal mechanism under typical fiber cutting angles was analyzed. The results indicate that when PCD milling cutter mills unidirectional CFRP with a constant 30° angular difference， both of normal cutting force（Fn）and tangential cutting force（Ft） follows a specific pattern. Compared to down milling， Fn reduces 25% at least and Ft reduces 40% at least in up milling， while the surface roughness Sa reduces 10% to 35%. Compared to dry cutting， nanofluid for minimal quantity lubrication machining Ft reduces 20% approximately， and cutting temperature decreases around 40%.

Key words: nanofluid minimum quantity lubrication, down/up milling, high speed milling, material removal model, carbon fiber reinforced plastic（CFRP）composite material

摘要： 采用正十二边形切削轨迹方法研究了碳纤维增强复合材料（CFRP）的高速切削性能，重点研究了冷却润滑条件、纤维切削角、切削速度和顺/逆铣对材料加工性能的影响，揭示了典型纤维切削角下的材料去除机理。研究表明：使用聚晶金刚石铣刀沿等差为30°的切削角侧铣单向CFRP时，法向切削力Fn和切向切削力Ft均遵循一个特定的规律。相较于顺铣，逆铣时的Fn最大减小25%，Ft最大减小40%，表面粗糙度Sa减小10%～35%。相较于干切削，纳米流体微量润滑切削下的Ft减小约20%，切削温度降低约40%。

关键词: 纳米流体微量润滑, 顺/逆铣, 高速铣削, 材料去除模型, 碳纤维增强复合材料

CLC Number:

TB332

ZHANG Lifeng, ZHANG Xiaoguang. Machining Performance and Material Removal Mechanism of High-speed Milling of CFRP with Variable Angle under Minimal Quantity Lubrication[J]. China Mechanical Engineering, 2023, 34(21): 2622-2628.

张立峰, 张晓光. 微量润滑变角度高速铣削碳纤维增强复合材料的加工性能与材料去除机理[J]. 中国机械工程, 2023, 34(21): 2622-2628.

References

［1］陈正文，阮晓峰，邹佳林，等. 磨料水射流切割碳纤维复合材料的表面粗糙度试验［J］. 中国机械工程， 2019， 30（11）：1315-1321.
CHEN Zhengwen， RUAN Xiaofeng， ZOU Jialin， et al. Surface Roughness Tests of CFRP Cutting by AWJ［J］. China Mechanical Engineering， 2019， 30（11）：1315-1321.
［2］郑志龙，赵玉刚，刘谦，等. 碳纤维增强复合材料水导激光加工实验研究［J］. 中国机械工程， 2023， 34（3）：344-351.
ZHENG Zhilong， ZHAO Yugang， LIU Qian， et al. Experimental Study on Water Jet Guided Laser Processing of CFRPs［J］. China Mechanical Engineering， 2023， 34（3）：344-351.
［3］ZHANG B Y， LI Y， WANG F J， et al. Machining Inclination Selection Method for Surface Milling of CFRP Workpieces with Low Cutting-induced Damage［J］. Composite Structures， 2023， 304：116495.
［4］逄显娟，岳世伟，黄素玲，等. 碳纤维/聚醚醚酮（CF/PEEK）复合材料摩擦磨损性能及抗摩擦静电特性研究［J］. 中国机械工程， 2023， 34（3）：277-286.
PANG Xianjuan， YUE Shiwei， HUANG Suling， et al. Tribological Properties and Anti Friction Electrostatic Properties of CF/PEEK Composites［J］. China Mechanical Engineering， 2023， 34（3）：277-286.
［5］ZHENG H， ZHANG W J， LI B W， et al. Recent Advances of Interphases in Carbon Fiber-reinforced Polymer Composites：a Review［J］. Composites Part B：Engineering， 2022， 233：109639.
［6］陈沛哲. PCD直刃铣刀侧铣CFRP的刀具磨损规律研究［D］. 大连：大连理工大学， 2022.
CHEN Peizhe. Research on Tool Wear of PCD Straight Edge Milling Cutter in Side Milling of CFRP［D］. Dalian：Dalian University of Technology， 2022.
［7］ZHANG L F， WANG S， QIAO W L， et al. High-speed Milling of CFRP Composites：a Progressive Damage Model of Cutting Force［J］. The International Journal of Advanced Manufacturing Technology， 2020， 106（3/4）：1005-1015.
［8］王泽刚，王福吉，卢晓红，等. 考虑左旋切削刃切削连续性的碳纤维增强树脂基复合材料铣削研究［J］. 中国机械工程， 2020， 31（8）：991-996.
WANG Zegang， WANG Fuji， LU Xiaohong， et al. Research on CFRP Milling Considering Continuity of Left-handed Cutting Edges［J］. China Mechanical Engineering， 2020， 31（8）：991-996.
［9］汪建新，吴耀文，张广义，等. 碳纤维增强复合材料水导激光切割试验研究［J］. 中国机械工程， 2021， 32（13）：1608-1616.
WANG Jianxin， WU Yaowen， ZHANG Guangyi， et al. Experimental Research of CFRP Cutting by Using Water Jet Guided Laser Processing［J］. China Mechanical Engineering， 2021， 32（13）：1608-1616.
［10］张立峰，王盛，李战，等. 纤维方向对单向C/SiC复合材料磨削加工性能的影响［J］. 中国机械工程， 2020， 31（3）：373-377.
ZHANG Lifeng， WANG Sheng， LI Zhan， et al. Effects of Fiber Direction on Grinding Performances for Unidirectional C/SiC Composite［J］. China Mechanical Engineering， 2020， 31（3）：373-377.
［11］武卫洲，刘雪峰，崔鑫，等. 基于细观模型的刃口半径对CFRP铣削过程影响［J］. 航空制造技术， 2022， 65（22）：60-67.
WU Weizhou， LIU Xuefeng， CUI Xin， et al. Influence of Cutting Edge Radius on CFRP Milling Process Based on Microsimulation［J］. Aeronautical Manufacturing Technology， 2022， 65（22）：60-67.
［12］CAI C Y， DANG J Q， AN Q L， et al. Surface Morphology Characterization of Unidirectional Carbon Fiber Reinforced Plastic Machined by Peripheral Milling［J］. Chinese Journal of Aeronautics， 2022， 35（2）：361-375.
［13］BI G J， WANG F J， FU R， et al. Wear Characteristics of Multi-tooth Milling Cutter in Milling CFRP and Its Impact on Machining Performance［J］. Journal of Manufacturing Processes， 2022， 81：580-593.
［14］ZOU F， DANG J Q， WANG X F， et al. Performance and Mechanism Evaluation during Milling of CFRP Laminates under Cryogenic-based Conditions［J］. Composite Structures， 2021， 277：114578.
［15］LIU C L， REN J X， SHI K N， et al. Investigation of Fracture Mechanism Evolution Model for UD-CFRP and MD-CFRP during the Milling Process［J］. Composite Structures， 2023， 306：116585.
［16］SONG Y， CAO H J， QU D， et al. Surface Integrity Optimization of High Speed Dry Milling UD-CF/PEEK Based on Specific Cutting Energy Distribution Mechanisms Effected by Impact and Size Effect［J］. Journal of Manufacturing Processes， 2022， 79：731-744.
［17］郑华林，王贵鑫，宁海峰，等. 基于有限元CFRP多次铣削过程中面下损伤研究［J］. 航空制造技术， 2022， 65（5）：36-42.
ZHENG Hualin， WANG Guixin， NING Haifeng， et al. Subsurface Damage Research of CFRP Multiple Milling Process Based on FEM Simulation［J］. Aeronautical Manufacturing Technology， 2022， 65（5）：36-42.
［18］SHEIKH-AHMAD J， HE Yanli， QIN Lei. Cutting Force Prediction in Milling CFRPs with Complex Cutter Geometries［J］. Journal of Manufacturing Processes， 2019， 45：720-731.

[1]	JIN Minglei1, 2, JIN Mingsheng1, 2, SONG Zhengjiang3, ZENG Xi1, 2, LI Yan1, 2, TANG Xuan1, 2. Material Removal Model of Center-inlet Elastic Polishing Tools [J]. China Mechanical Engineering, 2024, 35(09): 1659-1666.
[2]	ZHANG Lifeng, WANG Zixu, ZHANG Wangtong, DENG Yunfei, SUI He, GUO Zhiyong. Contrastive Experiments on Up and Down Grinding of Unidirectional Ceramic Matrix Composite C/SiC with Variable Angle [J]. China Mechanical Engineering, 2024, 35(02): 235-243.
[3]	SHI Meng, LI Zhuo, ZENG Xi, JI Shiming, HUANG Pengcheng, ZHENG Qianqian. Experimental Study on Abrasive Dilatancy and Processing of Pneumatic Grinding Wheels under Non-uniform Curvature Surfaces#br# [J]. China Mechanical Engineering, 2021, 32(10): 1191-1199.
[4]	LI Yousheng. Influences of TaC(NbC) on Cemented Carbide Tool Wear Resistance in High Speed Milling [J]. China Mechanical Engineering, 2020, 31(13): 1601-1605.
[5]	Liu Bo, Zhou Houming, Zhou Youhang, Zhang Gaofeng, Peng Ruitao. Analysis of Influence of Cutter Diameter on Mechanics Propertiesof Shrink-fit Holder and Cutting Tool [J]. China Mechanical Engineering, 2016, 27(04): 513-517,525.
[6]	LONG Dun-Zhong-1, 2, XIN Zhi-Jie-1, CHEN Xin-Quan-1, MIAO Hong-Bin-1. Chip Formation in High Speed Milling of Hardened Mold Steel [J]. China Mechanical Engineering, 2013, 24(14): 1939-1942,1950.
[7]	LIU Wei-Wei, LI Feng, LIN Jun-Hua, WEI Yuan. Research on Surface Roughness Based on SPSO in High Speed Milling of GH4169 [J]. China Mechanical Engineering, 2011, 22(22): 2654-2657,2771.
[8]	SU Yu, HE Ning, LI Liang. Experimental Study on High Speed Milling Titanium Alloys Using Cryogenic Minimum Quantity Lubrication [J]. China Mechanical Engineering, 2010, 21(22): 2665-2670.
[9]	Wang Xiaochun;Hu Yingning;Cao Jingyuan;Long Weiren;Su Jiaqiang. Study on Cutting Force for Milling Hardened Steel Arc Path with Micro-end Mill [J]. J4, 2009, 20(13): 0-1624.
[10]	Shen Zhigang;He Ning;Li Liang. Monitoring of Tool Wear in Hard Milling Process [J]. J4, 2009, 20(13): 0-1624.
[11]	Shi Feng;Dai Yifan;Peng Xiaoqiang;Song Ci. Three-dimensional Material Removal Model of Magnetorheological Finishing(MRF) [J]. J4, 2009, 20(06): 0-673.
[12]	Pang Junzhong, Wang Minjie, Duan Chunzheng, Yang Yu. Cutting Forces in High Speed Milling of Hardened Steel P20 and 45 [J]. China Mechanical Engineering, 2007, 18(21): 2543-2546.