Tool Wear Reduction Using Directional Milling Considering Cutting Angle in Carbon fiber Reinforced Plastic Machining

The abrasion of the cutting edge by hard carbon fibers during machining of carbon fiber reinforced plastics (CFRP) causes severe tool wear. In this process, the tool wear volume exhibits a strong dependence on the cutting angle (the angle between the fiber orientation and cutting direction). In industrial applications, the perimeters of CFRP workpieces are frequently machined via contour milling. However, it is difficult to avoid cutting angles that cause rapid tool wear in this type of milling. This study proposes a novel rough milling strategy to maintain the cutting angles within a specific range by adjusting the tool feed direction and radial depth of cut to reduce tool wear. In addition, to implement the proposed method for CFRP machining, a software is developed to generate the tool path. The effectiveness of the proposed method for tool life extension during milling of CFRP is experimentally investigated.