Abstract

The anisotropic nature of polymer composites presents many challenges for manufacturers to adopt appropriate machining processes. In the present investigation, end milling experiments were conducted on glass fiber reinforced polymer laminates with five varieties of customized cutting tools with different angles of rake and clearance. The performance of the tools was evaluated in terms of their machining force, surface roughness and delamination factor at spindle speeds in the range of 690–2500 rpm. From the observations, relatively high rake and angled clearance tools performed better than the rest of the tools under consideration in terms of delamination and machined surface finishing. The milling operations performed at a spindle speed of 1950 rpm produced better surface quality. Observations from SEM graphs, exposed surface defects due to milling, generated at lower spindle speeds of 690 rpm and at higher spindle speeds of 2500 rpm with the tool signature of low angle rake and angled clearance tools out of all five tools considered for the experiments.

摘要

聚合物复合材料的各向异性特性为制造商采用适当的加工工艺提出了许多挑战。在本研究中，使用五种具有不同前角和间隙角的定制刀具对玻璃纤维增​​强聚合物层压板进行了端铣削实验。在 690-2500 rpm 的主轴转速范围内，根据加工力、表面粗糙度和分层因素对刀具的性能进行了评估。从观察结果来看，在分层和机加工表面精加工方面，相对较高的前角和有角度的间隙刀具的性能优于其他考虑中的刀具。以 1950 rpm 的主轴速度进行的铣削操作产生了更好的表面质量。从 SEM 图中观察，