Experimental Study of Helical Milling Carbon Fiber Reinforced Plastics by Variable Parameters

In order to significantly reduce the defects of hole-making on Carbon Fiber Reinforced Plastics (CFRP), a scheme on the variable parameter helical milling experiments was carried out. First, the helical milling process was analyzed. Second, using the response surface methodology (RSM) in the experiments, the max exit tear value, aperture diameter and surface roughness Ra at the intermediate area were analyzed and the optimum combination of parameters was obtained: spindle speed 8962 r/min, helical speed 60 r/min, and pitch 0.207 mm at the hole entry and exit areas; spindle speed 6242 r/min, helical speed 87 r/min, and pitch 0.205 mm at the hole intermediate area. Last, the effect of milling direction on hole-making was obtained: up milling at the hole entry and exit areas and down milling at the hole intermediate area. The superiority of variable parameter helical milling experiment was verified: there were fewer defects such as burrs and tears at hole entry and exit areas; and the surface roughness Ra was 6.39% lower, the aperture deviation was from + 0.011 mm to -0.007 mm at the hole intermediate area. Therefore, the quality of hole-making by the variable parameter helical milling scheme was significantly improved.