Investigation of cBN Electroplated End-Mill Shape for CFRP Machining

2016 ◽  
Vol 874 ◽  
pp. 463-468
Author(s):  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa ◽  
Kiyofumi Inaba ◽  
...  
Keyword(s):  
High Efficiency ◽  
Cubic Boron Nitride ◽  
Rake Angle ◽  
Machining Process ◽  
End Mill ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
End Mills ◽  
High Thermal Resistance ◽  
Fiber Reinforced Plastics

Currently, carbon fiber reinforced plastics (CFRP) are being increasingly adopted in various fields. Thus, machining CFRP with high accuracy and high efficiency is required. In addition, machining stack materials composed of CFRP and titanium alloys is required. Therefore, in this study, a novel end-mill electroplated with a cubic boron nitride (cBN) abrasive, which has high thermal resistance, is proposed. In order to evaluate the influence of the base metal shape of the proposed end-mill on the machining process, several cBN-electroplated end-mills with different rake angles or chamfers were fabricated and used to cut CFRP. In addition, in order to evaluate the abrasive shape, a blocky abrasive was also electroplated on the end-mill. The results indicate that the negative rake angle is useful to restrain the progression of tool wear. However, in order to obtain the element of cutting and grinding, it is required that the rake angle should be positive. Moreover, the reasonable width of chamfer is effective for restraining the increase in CFRP temperature. Further, a sharp shaped abrasive can more effectively generate a CFRP with a sharp edge compared with a blocky shape abrasive.

Design of Exotic Materials Machining System

2013 ◽  
Vol 633 ◽  
pp. 36-46 ◽  
Author(s):  
John Mo ◽  
Song Lin Ding ◽  
Andrew Mackie ◽  
Milan Brandt ◽  
Shou Jin Sun ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Cubic Boron Nitride ◽  
Polycrystalline Diamond ◽  
Gain Scheduling ◽  
Control System Design ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Machining System ◽  
Design Requirements ◽  
Fiber Reinforced Plastics

New exotic materials such as titanium alloys and carbon fiber reinforced plastics require strong hard cutters made of cubic boron nitride or polycrystalline diamond. However, the traditional mechanical diamond grinding process is slow and causes damage to the workpiece. This chapter examines the design requirements of an electrical discharge machining system that can be used to machine polycrystalline diamond tipped carbide drills. A preliminary theoretical model is described but the system complexity requires a gain scheduling approach to the control system design.

Precision Drilling of Carbon Fiber Reinforced Plastics with Ball Nose End Mills

2016 ◽  
Vol 10 (3) ◽  
pp. 334-340 ◽  
Author(s):  
Shigehiko Sakamoto ◽  
◽  
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Cemented Carbide ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
End Mills ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced ◽  
Coated Cemented Carbide

Carbon Fiber Reinforced Plastics (CFRP) is well known as a Carbon Fiber Reinforced Plastics (CFRP) is well known as a difficult-to-cut material that has very strong physical and mechanical characteristics. Drilling technique of CFRP that is one of the most important cutting operations is currently carried out in the aviation and automotive industries, among others. Parts manufactured from CFRP have many precision holes used as rivet holes and for various purposes. There are typicaly many problems involved in the precision drilling processes of CFRP plate such as burrs, chippings and delaminations of composite materials, and the rapid wear of the drilling tools. In this research study, various twist drill bits, square end mills and ball noses end mills made of materials including cemented-carbide, TiAlN PVD-coated cemented carbide, Diamond-Like Carbon (DLC) coated cemented carbide and high-speed steel, are tested. CFRP drilling tests without coolant are carried out on vertical machining centers. It is found that the ball nose end mill is the most suitable for drilling CFRP composite materials.

High Aspect Ratio Machining of Carbon Fiber Reinforced Plastics by Electrical Discharge Machining Process

2020 ◽  
Author(s):  
Cibi Makudapathy ◽  
Murali Sundaram
Keyword(s):  
Carbon Fiber ◽  
Aspect Ratio ◽  
High Aspect Ratio ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics

Abstract Micromachining of Carbon Fiber Reinforced Plastics (CFRPs) is essential for numerous applications in several industries such as aerospace, automotive, defense, shipping, sporting goods, and biomedical industries. The major challenge in machining CFRP by electrical discharge machining (EDM) is due to the non-conductivity of epoxy material which is used as a binder for manufacturing these CRFPs. This study attempts a novel, yet simple approach to ensure the conductivity of the work piece through the entire machining process. Experiments were carried out in this work to assess the feasibility of machining high aspect ratio micro-holes in CFRP by micro EDM. The effect of process parameters such as voltage and feed-rate on the hole quality was studied. Using optimal process conditions, micro hole of 2500 µm deep with an aspect ratio of over 11 was achieved.

Verschleißmechanismen polymerbeschichteter Hartmetall-Werkzeuge beim Fräsen von CFK*/Wear mechanisms of polymer-coated carbide tools during milling of CFRP

2015 ◽  
Vol 105 (01-02) ◽  
pp. 29-34
Author(s):  
D. Becker ◽  
A. Gebhardt ◽  
M. Schneider
Keyword(s):  
Carbon Fiber ◽  
High Performance ◽  
Machining Process ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
High Performance Polymers ◽  
Tool Surface ◽  
Fiber Reinforced Plastics ◽  
Coated Carbide ◽  
Coated Carbide Tools

Das Hauptproblem beim Fräsen von CFK (kohlenstofffaserverstärktem Kunststoff) liegt im erhöhten Verschleiß der Schneide, welcher durch den Übertrag von CFK auf die Werkzeugoberfläche begleitet wird. Um den Verschleiß der Hartmetallwerkzeuge zu minimieren, wurden beim Fräsen von unidirektionalem und Gewebe-CFK neue Beschichtungen angewendet sowie analysiert. Diese Beschichtungen basieren auf antiadhäsiven und temperaturbeständigen Hochleistungspolymeren, die durch die Modifikation von Polytetrafluorethylen (PTFE) und Perfluorethylenpropylen (FEP) hergestellt wurden.   The main problem when machining CFRP (carbon fiber reinforced plastics) is the increased wear of the cutting edge, which is accompanied by the transfer of CFRP onto the tool surface. To minimize wear of carbide tools, new coatings were applied and analyzed for the machining process of unidirectional and woven CFRP. These coatings are based on non-adhesive and heat-resistant high-performance polymers, which consist of modifications of polytetrafluoroethylene (PTFE) and perfluoroethylenepropylene (FEP).

scholarly journals Investigation of Optimum Grinding Condition Using cBN Electroplated End-Mill for CFRP Machining

2021 ◽  
Vol 15 (1) ◽  
pp. 4-16
Author(s):  
Shinnosuke Yamashita ◽  
Tatsuya Furuki ◽  
Hiroyuki Kousaka ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Airline Industry ◽  
End Milling ◽  
Cubic Boron Nitride ◽  
Machining Process ◽  
End Mill ◽  
Machined Surface ◽  
Side Milling ◽  
Reinforced Plastics ◽  
Grinding Tool

Recently, carbon fiber reinforced plastics (CFRP) have been used in various applications such as airplanes and automobiles. In CFRP molding, there are unnecessary portions on the outer area. Therefore, a machining process is required to remove them. Cutting and grinding are conventionally used in the finish machining of CFRPs. End-milling allows the removal of most of these portions. However, uncut fibers easily occur during end-milling. In contrast, a precise machined surface and edge are easily obtained using a grinding tool. Therefore, this research has developed a novel cubic boron nitride (cBN) electroplated end-mill that combines an end-mill and a grinding tool. This is a versatile tool that can cut and grind CFRPs by changing the direction of rotation of the tool. In this study, the effectiveness of the developed tool is investigated. First, the developed tool machined the CFRP by side milling. Consequently, cBN abrasives that were fixed on the outer surface of the developed tool did not detach in certain cutting conditions. Next, in order to generate a sharp edge on the CFRP and restrict the increase in the CFRP temperature with the cBN electroplated end-mill, the optimum abrasive size and grinding condition were investigated through the design of experiments. Moreover, the effectiveness of the developed tool was verified by comparing it with a conventional tool. As a result, smaller burrs and uncut fibers were observed after final machining with the developed tool under the derived optimum condition than those with conventional tools. However, the desired surface roughness could not be achieved as required by the airline industry. Therefore, oscillating grinding was applied. In addition, the formula of the theoretical surface roughness while using the developed tool was derived using the theory of slant grinding. As a result, the oscillating condition that led to the required surface roughness was obtained by theoretical analysis. In addition, the required value for the airline industry was achieved by oscillating grinding.

Effect of Helical Drill Points on Delamination in Drilling Carbon Fiber Reinforced Plastics (CFRP)

2009 ◽  
Vol 76-78 ◽  
pp. 618-623
Author(s):  
Ping Zou ◽  
Xu Lei Yang ◽  
Xi You Li
Keyword(s):  
Carbon Fiber ◽  
Cutting Speed ◽  
Rake Angle ◽  
Cutting Condition ◽  
Fiber Reinforced ◽  
Extrude Material ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

A study of helical drill points for drilling carbon fiber reinforced plastics (CFRP) is presented. A helical drill point has an “S” contour with a radiused crown chisel that reduces the thrust force and make the drills self-centering. The S-shape chisel edge has a lower negative rake angle than a conventional chisel edge, and therefore may cut rather than extrude material. Experiments of drilling CFRP with helical drill points and conventional drill points were conducted. The results indicate that the helical drill points can reduce delamination significantly as compared to the conventional drill points under same cutting condition. Otherwise, delamination size decreases with increasing the cutting speed and increases with increasing the feed

Sign in / Sign up

Export Citation Format

Share Document