Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Machining carbon fiber reinforced polymers (CFRPs) presents challenges due to their abrasive nature and anisotropic properties.
• Optimizing machining parameters is crucial for achieving high-quality parts, managing tool wear, and minimizing environmental impact like dust emission.

Purpose of the Study:

• To determine an optimal machining process window for dry milling of CFRPs.
• To investigate the influence of machining conditions (spindle speed, feed rate) on key performance indicators: cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission.

Main Methods:

• Utilized analytical and empirical models to examine cutting temperature.
• Conducted systematic cutting experiments using a full factorial design on a CNC milling machine.
• Varied cutting speeds (10,000-20,000 rpm) and feed rates (2-6 µm/tooth).

Main Results:

• Spindle speed significantly impacts cutting temperature and fine particle emission.
• Feed rate influences cutting force, specific cutting energy, and tool wear.
• Optimal conditions for cutting force and tool wear were found at 10,000 rpm; cutting temperature remained below the glass transition temperature.

Conclusions:

• Established relationships between machining parameters and performance indicators for CFRP dry milling.
• Identified optimal machining parameters to balance part quality, tool performance, and dust emission.
• Validated experimental results with a predictive model, offering insights for process improvement.