Machining Characteristics of Composite Materials During Milling

Composite materials are widely used in aerospace, automotive, and engineering applications due to their high specific strength, corrosion resistance, and low weight. However, the heterogeneous and anisotropic structure of these materials significantly complicates the milling process. This paper analyzes the main features of composite materials milling, including the influence of fiber orientation, cutting parameters, thermal effects, chip formation mechanisms, surface defects, and tool wear. The study shows that feed rate has the greatest influence on fiber pull-out, fuzzing, and surface roughness, while cutting speed strongly affects tool wear. Due to the low thermal conductivity of composite materials, most of the generated heat is concentrated in the cutting tool, accelerating wear processes. Abrasive wear on the flank face is identified as the dominant wear mechanism during machining. The paper also reviews advanced approaches for improving machining performance, such as ultrasonic-assisted milling, variable stock removal strategies, intermittent cutting, and pre-deformation of the material layer before cutting. The obtained results provide a scientific basis for selecting rational machining conditions and developing efficient methods for increasing productivity, improving surface quality, and extending tool life during the milling of glass fiber reinforced polymer composites.

Composite materials, milling, machining characteristics

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