The Effect of Carbon Fiber Types on Tool Wear During Edge Trimming of 0 deg, 45 deg, 90 deg, and 135 deg Carbon Fiber-Reinforced Plastic Laminates

Abstract

Carbon fiber-reinforced plastics (CFRP) composites are difficult-to-machine materials due to extensive tool wear. This article investigates the impact of carbon fiber types on tool wear in edge-trimming CFRPs, each with the ply angle of 0 deg, 45 deg, 90 deg, or 135 deg, using uncoated tungsten carbide endmills at the high spindle speed of 6000 rpm and the constant feed of 0.0508 mm/rev. Three distinct types of carbon fiber tows, including T300 as standard modulus (SM), IM-7 as intermediate modulus (IM), and K13312 as high modulus (HM), have been vacuum infused into CFRP laminates and edge trimmed to investigate wear characteristics. Three wear criteria measured are flank wear, edge rounding radii, and worn area. The results show that tool wear is influenced by carbon fiber properties, such as fiber tensile strength, tensile modulus, and fiber microstructure. Overall, IM carbon fibers with the highest tensile strength produced the most extensive tool wear due to the abrasive carbon fibers. Of four fiber directions, the largest tool wear was obtained from the 45 deg angle, while the lowest tool wear occurred in the 0 deg angle.