The application of end mills in the Processing of glass fiber composite materials

In the processing of glass fiber composite materials, end mills need to specifically optimize the tool structure and cutting parameters, and take anti-delamination measures. The following is a specific analysis:

Tool selection and improvement

Tool material: Due to the high abrasiveness of glass fiber composite materials, tools should be made of materials with high hardness and wear resistance, such as cemented carbide, and the use of coating techniques (such as TiAlN coating) should be considered to enhance the durability of the tools.

Tool structure: In light of the characteristics of glass fiber composite materials, the geometric structure and angles of the tool should be optimized to reduce cutting force and cutting heat. For instance, adopting a smaller helix Angle can reduce axial resistance, minimize burrs and delamination.

Special tools: For certain specific processing requirements, such as the need to prevent fibers from being lifted or delaminated, specialized composite material end mills can be used. These tools usually have special edge treatments and groove designs.

Cutting parameter optimization

Cutting speed: The selection of cutting speed should comprehensively consider the tool material, workpiece material and processing requirements. Excessively high cutting speeds may lead to accelerated tool wear or a decline in the surface quality of the workpiece, while excessively low cutting speeds may reduce processing efficiency.

Feed rate: The selection of feed rate should ensure that the tool can stably cut the workpiece while avoiding excessive cutting force and cutting heat. For glass fiber composite materials, since a large amount of cutting heat may be generated during the cutting process, the selection of feed rate is particularly important.

Cutting depth: The cutting depth should be determined based on the processing requirements of the workpiece and the rigidity of the cutting tool. Excessive cutting depth may cause the tool to bend or vibrate, thereby affecting the machining accuracy and surface quality.

Processing strategies and techniques:

Layer-by-layer processing: For thicker glass fiber composite material workpieces, a layer-by-layer processing strategy can be adopted, that is, only one layer of material is cut at a time, and then the cutting depth is gradually increased to reduce the influence of cutting force and cutting heat on the workpiece and the tool.

Cooling and lubrication: During the machining process, appropriate coolant or lubricant should be used to lower the cutting temperature and reduce tool wear. For glass fiber composite materials, since a large amount of dust and debris may be generated during the cutting process, the selection of coolant should take into account its cleaning and chip removal capabilities.

Preventing delamination: When processing glass fiber composite materials, special attention should be paid to preventing the occurrence of delamination. This can be achieved by optimizing the tool structure, selecting appropriate cutting parameters and adopting appropriate processing strategies.