Citation: | WANG Fuji, GE Lianheng, HU Xiaohang, et al. Longitudinal-torsional ultrasonic vibration-assisted milling performance and process optimization of CF/PEEK unidirectional plates[J]. Acta Materiae Compositae Sinica, 2024, 41(9): 5053-5069. DOI: 10.13801/j.cnki.fhclxb.20240724.001 |
Compared with traditional carbon fiber reinforced polymer composites (CFRP), carbon fiber reinforced thermoplastic polymer composites (CFRTP) are widely used in the manufacturing of high-end equipment such as aerospace and transportation due to their advantages of high toughness, good thermal stability, and strong impact resistance. Although CFRTP components are typically produced using near-net-shape strategies, secondary machining is still indispensable to meet the high precision and dimensional requirements during the connection and assembly process.As a typical difficult-to-machine material, CFRTP's heterogeneity and anisotropy make it extremely challenging to machine, resulting in poor machining quality. Defects such as fiber pull-out and fiber-resin debonding are prone to occur during the machining, severely affecting the assembly precision and service reliability of the components. Moreover, compared to CFRP, CFRTP possesses greater ductility, leading to more severe subsurface fiber fractures and bending deformations during machining. These characteristics have significantly hindered the application of CFRTP. Therefore, to promote the application of CFRTP, optimized processing strategies must be developed to reduce these defects and enhance the overall machining quality.
This paper takes the commonly used CFRTP material - carbon fiber reinforced polyetheretherketone (CF/PEEK) as an example and introduces the longitudinal-torsional ultrasonic vibration-assisted milling (UVAM) to conduct a multi-objective optimization study for CF/PEEK. By comparing the UVAM with conventional milling (CM), the influence of machining parameters on output characteristics, including cutting force, cutting temperature, surface roughness, and damage defects, is explored. Subsequently, through regression analysis, mathematical models of surface roughness, defects, and processing parameters are established. Variance analysis (ANOVA) and residual analysis are employed to verify the validity of the model coefficients. Finally, the non-dominated sorting genetic algorithm (NSGA-II) is adopted to solve the multi-objective optimization problem. With surface roughness, tool life, and defect conditions as optimization objectives, a multi-objective optimization study of the milling process for CF/PEEK composites is conducted. The results of this study can provide theoretical foundations and practical guidance for optimizing the processing technology of CF/PEEK
(1) Compared to conventional milling (CM), the ultrasonic longitudinal-torsional vibration-assisted milling (UVAM) is capable of reducing the cutting force. Within the analysis range, the cutting force decreases by 14.3-28.7% at different rotational speeds, 4-47% with varying feed rates per tooth, and 18.3-54.1% with different radial depths of cut. Furthermore, the surface quality achieved by UVAM is significantly superior to that of CM, with a reduction in roughness (Sa) ranging from 15.8% to 66.9%. (2) Under suitable cutting conditions, UVAM can effectively reduce cutting temperatures, minimize wear, and enhance tool life. (3) Utilizing the Non-dominated Sorting Genetic Algorithm II (NSGA-II), an optimal set of processing parameters has been obtained. The average relative errors between the experimental and predicted values for surface roughness (), defect factor (), and edge radius wear (Δ) are 7.29%, 14.9%, and 5.14%, respectively.Conclusions:This paper focuses on the UVAM milling process of CF/PEEK unidirectional laminates using a straight-edged milling cutter. A comparative analysis is conducted between UVAM and CM in terms of cutting force, cutting temperature, edge radius wear, surface roughness, and burr defect factor. Multi-objective optimization is performed using the NSGA-II, and the main conclusions are summarized as follows: (1) Compared to CM, UVAM exhibits high-frequency pulsing and intermittent contact characteristics. These properties contribute to enhancing the impact effect during cutting and reducing the duration of contact between the cutting tool and the material. These features enable UVAM to effectively reduce cutting forces, facilitate efficient removal of fibers and resin, and improve machining quality.(2) On one hand, the high-frequency torsional and longitudinal vibrations in UVAM facilitate the removal of fibers and resin, resulting in reduced cutting forces and decreased heat generation. On the other hand, the introduction of longitudinal vibration can generate additional friction, accelerating tool wear and heat production. Consequently, it is crucial to optimize the process parameters for UVAM cutting processes. When selecting processing parameters, it is necessary to comprehensively consider these factors to achieve optimal machining results.(3) For UVAM machining of CF/PEEK, the NSGA-II proposed in this paper demonstrates good feasibility and effectiveness in solving multi-objective optimization problems. Future research will build upon this algorithm to further optimize and explore its application in different materials, various cutting tools, and a wider range of machining conditions.
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