Experimental investigation on tool wear and hole quality in helical milling of CFRPs

As a typical difficult-to-machine material, the strong wear resistance and high hardness of carbon fiber in carbon fiber–reinforced plastics (CFRPs) lead to rapid tool wear during the cutting process, exacerbating surface damage of the hole and significantly increasing production costs. The investigation of tool wear has always been the pivotal focus in low-cost manufacturing. However, no similar work has been reported yet in tool wear of CFRP helical milling To fill this gap, this paper aims to conduct a theoretical analysis of the tool wear mechanism in helical milling of CFRPs and summarize the trends in tool wear under different cutting amounts as well as the impact of tool wear on cutting force and hole quality. Tool wear characteristics in terms of helical milling were studied carefully. Discussions on the tool wear morphology, cutting parameters, cutting force, and hole wall roughness were also provided. The findings in this paper might offer guidance on tool wear mechanisms for extending tool life and increasing hole-making quality in helical milling of CFRPs.