Tool wear of diamond interlocked tools in routing of CFRP composites

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Janardhan, Prashanth
Cheraghi, S. Hossein
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Though all CFRP materials are manufactured to their near net shape, they require a secondary machining operation for their final assemblage. In doing so, the main problem encountered is damage that results from delamination. Since CFRP materials are highly abrasive in nature, their machining requires that both the cutting and shearing of fibers occur simultaneously. Hence, cutting tools should incorporate tool geometry that effectively responds to these requirements. In this research, the routing of CFRP composite materials was done with a diamond interlocked tool. Experiments were conducted by varying spindle speed and feed rate, keeping the radial depth of cut constant. The main objective of this research was to develop a quantifiable method of tool wear measurement in a diamond interlocked tool and thus determine the time for tool replacement. Unlike the conventional cutting tools, the diamond interlocked tool has a unique tool geometry used for machining FRP materials, and poses substantial challenge in the process of tool wear measurement. However, four methods of direct wear measurement techniques---fracture wear, maximum flank wear, tip recession and wear area, were assessed. Insensitivity of these direct wear measurements with respect to the process parameters namely spindle speed and feed rate, made it difficult to determine the time for tool replacement time. Furthermore, an indirect method of tool wear quantification was developed by using delamination factor and power, against cutting distance. The values of tool life were then analyzed in ANOVA, the model produced significant result at 95% confidence level, and a generalized tool life equation and power equation for tool replacement time were developed.

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Thesis (M.S.)--Wichita State University, College of Engineering, Industrial and Manufacturing Engineering.
"December 2005."
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