An anti-wear tool structure with integrated-micro hybrid cutting edges for milling of carbon fiber–reinforced plastics composites

In the milling of CFRP, the most widely used cemented carbide tool is vulnerable to severe wear. Focusing on the issue, the study aims to reduce the tool wear extent by the way of designing high-performance tool structure. A calculation method of tool wear volume is established, characterized by considering the dynamic influences of temperature variation in the continuous milling process on the hardness of tool surface. With the method, the anti-wear performance of the micro cutting edge and the integrated cutting edge which are most commonly used in machining of CFRP is analyzed, under an error within 12%. It is indicated that the anti-wear performance of the integrated cutting edge is much better than the micro cutting edge, while the latter one has the inherent advantage of effectively removing the material of CFRP. Based on this, a hybrid tool structure which takes advantage of both the two types of cutting edge is proposed. Results of tool life test suggest that the tool life of the proposed tool is about 300% over than that of multitooth tool.