Study on Modelling of Axial Force Based on Energy Method in Tilted Helical Milling of CFRP

doi:10.3901/JME.2025.07.245

Abstract

Abstract: Carbon fiber reinforced plastics (CFRP) are widely used in aerospace and other defence fields because of their excellent properties such as high specific strength, corrosion resistance and fatigue resistance, etc. However, due to their anisotropic properties, the hole making process is very prone to produce defects. Therefore, it focuses on improving the quality of hole-making and reducing the axial force in tilted helical milling of CFRP, a model to predict the tilted helical milling axial force of ball-end mills is set up based on the energy method for the first time. Considering the kinematics of helical milling and geometrical model of the ball-end mills as well as the influence of the inclination angle, the cutting edge of the ball-end mills is decomposed into infinitesimal bevelled angle cutting units. The micrometric cutting forces are directly related to the cutting energy in the equivalent plane, thus the friction and cutting fracture energies as well as the energy consumed to form the new surface is analyzed in turn. The shape and volume of undeformed chips at the exit stage of the hole are described, and the effect patterns of different parameters on the axial force, delamination damage and burr coefficient in helical milling of CFRP are comparatively investigated. It was shown that the tilted angle directly affected cutting speed, material removal mode and the axial force of spherical cutting edge during the hole-making process, and then affected the hole exit quality.

Key words: CFRP, tilted helical milling, energy method, oblique cutting, ball-end mill

CLC Number:

TG156

WANG Haiyan, YU Wanchun, FENG Yan, WANG Qingchao. Study on Modelling of Axial Force Based on Energy Method in Tilted Helical Milling of CFRP[J]. Journal of Mechanical Engineering, 2025, 61(7): 245-258.

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