Thermal aspects in machining CFRPs: effect of cutter type and cutting parameters

The problem of heat generation and distribution in edge trimming of carbon fiber-reinforced polymers (CFRP) was investigated. The heat diffusion problem in the cutting zone was modeled numerically and an inverse head conduction technique was applied to determine the heat partition. Measurements of boundary temperatures allowed the determination of the proper magnitude of heat flux applied to the workpiece and the cutting tool. It was found that less than 16% of the total heat is conducted into the workpiece and that higher feed speeds allowed less heat to conduct into the workpiece. The depth of heat penetration into the workpiece caused the temperature to reach the glass transition temperature of the epoxy only for the slower feed speed. When tested at the same feed per revolution, a PCD 2-flute end mill was the most effective tool in removing the heat from the cutting zone as compared to burr tools.