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Effect of chatter on material removal during surface milling of thin-walled carbon fiber–reinforced plastic (CFRP) components

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Abstract

Due to the weak rigidity of thin-walled carbon fiber–reinforced plastics (CFRPs), these materials are prone to chatter during the surface milling process that results in unstable cutting. Due to the laminated and anisotropic characteristics of CFRP, different layers of materials are unevenly removed during the cutting process, which reduces the quality of the processed surface. Moreover, different fiber directions greatly affect chatter. Accordingly, the chatter of CFRP is a complicated phenomenon. Currently, conventional methods to suppress chatter have limited performance. In the present study, the influence of the fiber direction angle on chatter during the milling process of a CFRP unidirectional plate is analyzed, and the removal of different layers caused by chatter is studied. Based on the Taguchi experiment, the effects of various process parameters on flutter were analyzed. The obtained results show that the maximum amplitude can be achieved when the fiber direction angle is set to 135°. In this case, the spindle speed has the most significant effect on chatter. It is found that changing the process parameters can effectively suppress the chatter and improve the surface quality. This article provides a basis to establish theoretical models of chatter behavior in thin-walled CFRP surface milling, and find appropriate methods to suppress chatter.

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Funding

This work is supported by the National Key R&D Program of China (Grant No. 2018YFA0702803); Liaoning Revitalization Talents Program (Grant No. XLYC1801008, XLYC1902014, XLYCYSZX1901); and Science and Technology Innovation Foundation of Dalian (Grant No. 2019CT01, 2021RD08).

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Authors and Affiliations

  1. Key Laboratory of High-Performance Manufacturing for Advanced Composite Materials, Liaoning Province, Dalian University of Technology, Dalian, China

    Fuji Wang, Jun Deng, Boyu Zhang, Lelin Yang & Yongquan Lin

Authors
  1. Fuji Wang
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  2. Jun Deng
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  3. Boyu Zhang
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  4. Lelin Yang
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  5. Yongquan Lin
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Contributions

Fuji Wang and Jun Deng conceived and designed the study. Jun Deng and Lelin Yang performed the experiments. Jun Deng and Boyu Zhang wrote the paper. Boyu Zhang, Lelin Yang, and Yongquan Lin reviewed and edited the manuscript. All authors read and approved the manuscript.

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Correspondence to Boyu Zhang.

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Wang, F., Deng, J., Zhang, B. et al. Effect of chatter on material removal during surface milling of thin-walled carbon fiber–reinforced plastic (CFRP) components. Int J Adv Manuf Technol 122, 2899–2910 (2022). https://doi.org/10.1007/s00170-022-10078-6

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