Experimental Study Of Carbon Fiber Reinforced Composite Material Forming Alveolar Milling

As one of the most advanced materials in the world, CFRP has so many superior priorities which the traditional material cannot be match. But the low thermal conductivity, anisotropy and laminated structural lead to the high cutting force, tool wear seriously and bad machined surface quality when form milling the CFRP. This makes CFRP cannot be spread in the world. This paper mainly study on form milling technique on internal tooth slot of the sabot part and provides technical support for CFRP using on sabot.The mainly content of the paper and the conclusion bellowing:(1) Form milling the internal tooth slot with three different numbers of teeth tools made in cemented carbide (CC) and one PCD tool to investigate the cutting force and the cutting force change law. The results show the cutting force increases when the feeding speed increases or the cutting speed decreases for all four tools; in the same cutting parameters, the four tooth CC tool get the lowest force in the same material and the two tooth CC tool get the highest force; in the same cutting parameters, the PCD tool gets a lower cutting force than the CC tool;(2) Analyzing the machined surface quality in both macroscopic and microcosmic ways and the results show that in the macroscopic way, there are spalling, burr, large surface layer spalling and large area uncutted; in the microcosmic way, there are fiber pulling-out, fiber unstick, delamination and resin uneven-coating; among the four tools, PCD tool gets the best machined surfaced quality while the cutting speed is295m/min and the feeding speed is0.0113mm/t; the four tooth CC tool gets the second best quality position;(3) Using the plastic plate improves the milling-exit surface quality and changing the feeding speed to zero in specific position makes the machined surface in slot smooth and clean;(4) In order to study on the tool wear, an experiment using the CC tool and PCD tool which have the same structure was carried out. Using the stereoscopic microscope and SEM to observe the morphology of the rake face and the flank face. The results show that after form milling on CFRP, the CC tool gets tipping, micro-tipping, tool nose collapse and crater wear; the PCD tool gets grain shedding, tipping, micro-tipping and surface-peeling off; the PCD tool gets a large way better abrasion than the CC tool; the cutting force get higher when the tool abrasives.