Analytical model for revealing tool wear law during edge trimming of carbon fiber reinforced plastics composites

This study proposes a novel tool wear model for the edge trimming process of CFRP. The main innovation is that the model respectively considers the actual wear state of planar flank face and semi-cylindrical cutting edge. Besides, for the whole wear process, the model illustrates the dynamic wear condition by introducing a varying wear coefficient determined by the instantaneous force-temperature condition and relative movement distance. The analytical results on tool wear law suggest that the cutting edge wear mainly depends on tool nose rigidity and the practical contacting distance with the CFRP workpiece. To suppress the cutting edge wear, it is recommended to reduce the rake angle and flank angle to improve the rigidity, and to select low spindle speed and high feed rate to decrease the practical cutting distance. For the flank face, its wear is mainly determined by the flank angle and bouncing back height of the machined surface. To reduce its wear, a large flank angle, high spindle speed and low feed rate is recommended. Since the strategies for reducing the wear of cutting edge and flank face is contradictory, to more effectively reduce the whole tool wear, it is priority to reduce the cutting edge wear.