Evaluation of millingtrimming performances for CFRP material utilizing various burrrouter tool geometrical features

Mohd Hasni, Mohamad Afiq Asna (2022) Evaluation of millingtrimming performances for CFRP material utilizing various burrrouter tool geometrical features. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Carbon Fiber Reinforced Polymer (CFRP) has found significant application in a variety of industrial sectors, particularly in the aerospace and automotive industries, due to its superior mechanical properties such as high strength, light weight, and corrosion resistance. The objective of the experiment was to study the optimum router tool geometry for the specific CFRP materials. The second objective of this research is to investigate the effect of the surface quality and the tool wear when various tool geometry of router type is used during edge trimming of CFRP material. Finally, to propose the most optimal burr/router tool geometry for trimming a specific CFRP material. The selected study material was a CFRP panel with a thickness of 3.25 mm and a total of 28 plies. Three different types of tool geometries manufactured of tungsten carbide material with the same diameter, 6.35 mm, while varying in the number of flutes and helix angle were successfully studied. The Model Pro II MDX-540 was used to trim the CFRP edges. The surface roughness of panel materialm is measured with the Mitutoyo Surftest SJ-410. A Kistler Dynamometer type 9257B was used to measure the cutting force. A Nikon MM-800 measuring microscope was used to evaluate tool wear. Following the conclusion of three cutting tool processes, all data gathered was evaluated. To prevent CFRP damage during edge trimming, an ideal set of machining parameters is used. A spindle speed of 5938 RPM, a cutting speed of 118.47 m/min, and a feed rate of 297mm/min are the optimal machining setup. For each tool, the machine mode is down and up cutting. Cutting tool 1 (T1) provided the least amount of surface roughness when compared to the overall mean value in both machining directions, according to the data. The cutting tool 2 (T2), on the other hand, has the highest surface roughness value. In the meantime, cutting tool type 3 (T3) is halfway between the other two tool types. In comparison to T1, when the tip of the pyramid cutting edge tool is really obviously smooth, tool wear observations show evident fractures at T2 and T3.

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