Analytical model for revealing tool wear law during edge trimming of carbon fiber reinforced plastics composites

Abstract

This study proposes a novel tool wear model for the edge trimming process of carbon fiber-reinforced plasticities (CFRPs). The main innovation is that the model considers the actual wear state of both the planar flank face and the semicylindrical cutting edge. In addition, for the whole wear process, the model illustrates the dynamic wear condition by introducing a varying wear coefficient determined by the instantaneous force‒temperature condition and relative movement distance. The analytical results of the tool wear law suggest that cutting edge wear depends on tool nose rigidity and the practical contact distance with the CFRP workpiece mainly. To suppress cutting edge wear, reducing the rake angle and flank angle to improve rigidity and selecting a low spindle speed and high feed rate to decrease the practical cutting distance are recommended. The wear of the flank face is mainly determined by the flank angle and bouncing back height of the machined surface. To reduce its wear, a large flank angle, high spindle speed, and low feed rate are recommended. Since the strategies for reducing the wear of the cutting edge and flank faces are contradictory, to reduce tool wear more effectively, reducing cutting-edge wear is prioritized.