Optimal milling conditions for carbon/epoxy composite material using damage and vibration analysis

The use of composite parts, especially in aeronautics, is increasing at an exponential rate. However, machining of this material is complicated due to different phenomena such as delamination, burned resin, and cutting edge failure. The aim of the present study is to introduce a new method for optimizing cutting conditions, using a correlation between vibration and machining defects. Down milling of a carbon/epoxy composite material with a single polycrystalline diamond insert was performed. To minimize the number of experiments, a central composite design with 20 combinations was studied, using parameters such as cutting speed, depth of cut, and feed rate. Vibration levels were measured for each cutting condition. Results obtained from the analysis of variance confirm that the mathematical models used in this study could adequately describe the performance indicators. A vibration criterion was defined to describe the regions with and without defects of the machining. This technique validated through testing should help the operator to choose the optimal cutting conditions.

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