Machining optimisation in carbon fibre reinforced composite materials

Abstract

By virtue of their characteristics, the applications of composite materials based on carbon reinforced plastic (CFRP) have been increasing considerably. Thus new manufacturing process and production techniques must be developed to ensure high precision and good surface quality of the components. As a result of this manufacturing scenario, it is necessary to study the machining process. This work reports practical experiments in turning, to study the performance of different tool materials such as ceramics, cemented carbide, cubic boron nitride (CBN), and diamond (PCD). The results show that only diamond tools are suitable for use in finish turning. An optimisation methodology was used in rough machining to determine the best cutting conditions. The tests were carried out with cemented carbide tool at various cutting speeds. In the optimisation methodology were used the cutting length as the tool replacement criterion and some parameters were monitored such as the feed and cutting forces that can used as a safety system. Finally, it is concluded that the optimisation of the cutting conditions is extremely important in the selection of the tools and cutting conditions to be used in the CFRP manufacturing process.