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Experimental study on surface defect area, chip behavior and tool wear of AFRP during spiral milling
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Ru LI 2
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Na LI 2
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1
Qilu Institute of Technology, Jinan 250200,China
 
2
Qilu Institute of Technology, Jinan 250200, China
 
3
Beijing Technology and Business University, Beijing 100048, China
 
 
Corresponding author
Lin WANG   

Qilu Institute of Technology, Jinan 250200,China
 
 
 
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ABSTRACT
A study on the spiral milling experiment of AFRP was carried out to analyze the milling surface morphology, defective area, chip morphology, tool wear, cutting temperature, and milling force, focusing on the milling mechanism and giving analytical explanations, mainly discussing the behavioral changes of composite chips. It is found that the t-test and the mathematical model based on the response surface method show that the area of surface defects is significantly affected by the feed speed, which gradually decreases with the increase of the feed speed; at the same time, it is found that in a specific range of milling parameters, the friction increases, the temperature rises significantly, and the resin matrix has a tendency to melt. It is stretched and extended into long strips, forming a special composite chip. For the milling force, the average error rates of the milling forces Fx, Fy, and Fz are 3.53%, 25.65%, and 14.75%, respectively, according to the established milling force mathematical model. The prediction results are relatively accurate, and it was also found that Fx, Fy are significantly affected by the interaction of cutting speed and feed speed. The study shows that tool wear is mainly in the form of bonding off and chipping of the tip of the tool due to alternating loads. Increasing the feed speed increases the actual contact area of the tool-workpiece and the tool-chip. It enhances the extrusion effect on the milling surface, effectively suppressing the surface burr, and the surface defective area better characterizes the surface morphology of the milling hole compared with the length of the burr and the hole-making deviation. Increasing the feed speed can make the cutting-edge sharpness enhancement and shear effect more and more significant, and composite chip serration intensified; when further increasing the feed speed will make the tool-workpiece contact area much larger than the tool-chip contact area, chip impact on the tool to weaken the role of milling force is reduced.
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