Effect of Machining Settings and Tool Geometry on Surface Quality After Machining of Al/CFRP Sandwich Structures
Elżbieta Doluk, Anna Rudawská
Abstract
The paper describes the eff ect of cutting parameters and tool geometry on the surface quality after machining of an Al/ CFRP (aluminium alloy/ Carbon Fibre Reinforced Plastics) sandwich structure. A two-layer sandwich structure made of an EN AW 2024 aluminium alloy and Carbon Fibre Reinforced Plastics (CFRP) was examined. The experiment used the process of peripheral milling. The experiment investigated the eff ects of cutting speed (v c ), feed per blade (f z ) and helix angle ( s ) on surface quality as defi ned by diff erences in the height of materials. It was also analysed how the machining conditions described above aff ected the values of cutting force components. In the experimental stage of the study, uncoated, double-bit carbide mill cutters with working diameter D c = 12 mm and a variable helix angle ( s = 20, s = 35, s = 45) were used. The results have shown that cutting parameters and tool geometry do aff ect the surface quality and cutting forces after milling of the sandwich structure. The lowest material height diff erence was achieved when machining with the helix angle s = 45, cutting speed v c = 300 m/min and feed per blade f z = 0.08 mm/blade. The highest material height diff erence occurred after machining under the following conditions: v c = 300 m/min, f z = 0.08 mm/min, s = 20. The minimum cutting force value was obtained for cutting parameters: v c = 80 m/min, f z = 0.08 mm/blade during milling with the helix angle s = 45. The maximum cutting force was recorded during machining with the helix angle s = 20, cutting speed v c = 400 m/min and feed per blade f z = 0.08 mm/blade.