Tool wear, mechanistic force modeling, and surface finish in CFRP milling

Junbeom Son; Chinmay Mungale; Sweta Baruah; Uday Vaidya; Tony Schmitz

doi:10.1016/j.jmapro.2025.03.068

Tool wear, mechanistic force modeling, and surface finish in CFRP milling

Junbeom Son
, Chinmay Mungale
, Sweta Baruah
, Uday Vaidya
, Tony Schmitz

Research output: Contribution to journal › Article › peer-review

13 Scopus citations

Abstract

This paper describes wear testing for two tool coatings, AlTiCrN and diamond, while milling a Toray 3900 prepreg system with plain weave carbon fiber architecture, T-830H-6 K fiber type, and 40 weight percentage epoxy resin. The testing objective is to establish the relationship between tool wear and: 1) the growth in cutting force coefficients for a mechanistic milling force model; and 2) degradation of areal roughness for machined CFRP surfaces. Flank wear width is used to quantify tool wear. It is observed that the diamond coating outperforms the AlTiCrN coating. Abrasive wear on the flank face is seen to be the dominant wear mechanism for the AlTiCrN coating with linear increases in flank wear width, areal roughness, and cutting force coefficients as volume is removed.

Original language	English
Pages (from-to)	1397-1415
Number of pages	19
Journal	Journal of Manufacturing Processes
Volume	141
DOIs	https://doi.org/10.1016/j.jmapro.2025.03.068
State	Published - May 15 2025
Externally published	Yes

Funding

This manuscript has been authored in part by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the DOE. The US Government retains and the publisher, by accepting the article for publication, acknowledges that the US Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Keywords

CFRP
Cutting force
Milling
Surface finish
Tool wear

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10.1016/j.jmapro.2025.03.068

Cite this

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title = "Tool wear, mechanistic force modeling, and surface finish in CFRP milling",

abstract = "This paper describes wear testing for two tool coatings, AlTiCrN and diamond, while milling a Toray 3900 prepreg system with plain weave carbon fiber architecture, T-830H-6 K fiber type, and 40 weight percentage epoxy resin. The testing objective is to establish the relationship between tool wear and: 1) the growth in cutting force coefficients for a mechanistic milling force model; and 2) degradation of areal roughness for machined CFRP surfaces. Flank wear width is used to quantify tool wear. It is observed that the diamond coating outperforms the AlTiCrN coating. Abrasive wear on the flank face is seen to be the dominant wear mechanism for the AlTiCrN coating with linear increases in flank wear width, areal roughness, and cutting force coefficients as volume is removed.",

keywords = "CFRP, Cutting force, Milling, Surface finish, Tool wear",

author = "Junbeom Son and Chinmay Mungale and Sweta Baruah and Uday Vaidya and Tony Schmitz",

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T1 - Tool wear, mechanistic force modeling, and surface finish in CFRP milling

AU - Son, Junbeom

AU - Mungale, Chinmay

AU - Baruah, Sweta

AU - Vaidya, Uday

AU - Schmitz, Tony

PY - 2025/5/15

Y1 - 2025/5/15

N2 - This paper describes wear testing for two tool coatings, AlTiCrN and diamond, while milling a Toray 3900 prepreg system with plain weave carbon fiber architecture, T-830H-6 K fiber type, and 40 weight percentage epoxy resin. The testing objective is to establish the relationship between tool wear and: 1) the growth in cutting force coefficients for a mechanistic milling force model; and 2) degradation of areal roughness for machined CFRP surfaces. Flank wear width is used to quantify tool wear. It is observed that the diamond coating outperforms the AlTiCrN coating. Abrasive wear on the flank face is seen to be the dominant wear mechanism for the AlTiCrN coating with linear increases in flank wear width, areal roughness, and cutting force coefficients as volume is removed.

AB - This paper describes wear testing for two tool coatings, AlTiCrN and diamond, while milling a Toray 3900 prepreg system with plain weave carbon fiber architecture, T-830H-6 K fiber type, and 40 weight percentage epoxy resin. The testing objective is to establish the relationship between tool wear and: 1) the growth in cutting force coefficients for a mechanistic milling force model; and 2) degradation of areal roughness for machined CFRP surfaces. Flank wear width is used to quantify tool wear. It is observed that the diamond coating outperforms the AlTiCrN coating. Abrasive wear on the flank face is seen to be the dominant wear mechanism for the AlTiCrN coating with linear increases in flank wear width, areal roughness, and cutting force coefficients as volume is removed.

KW - CFRP

KW - Cutting force

KW - Milling

KW - Surface finish

KW - Tool wear

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DO - 10.1016/j.jmapro.2025.03.068

M3 - Article

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JO - Journal of Manufacturing Processes

JF - Journal of Manufacturing Processes

ER -

Tool wear, mechanistic force modeling, and surface finish in CFRP milling

Abstract

Funding

Keywords

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