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<p>Carbon fiber reinforced polyetheretherketone (CF/PEEK) multidirectional plate material is used in new energy vehicles, aerospace and other fields due to its excellent mechanical properties and corrosion resistance. Due to the disparities in material properties between PEEK and carbon fiber, conventional milling operations often result in machining defects. This paper employs ultrasonic assisted milling (UAM) technology for the machining of CF/PEEK multidirectional composite laminates. First, a motion trajectory model for a specific point on a cutting edge during ultrasonic assisted milling is established, and the intermittent cutting behavior induced by axial vibration is analyzed, thereby establishing the theoretical foundation for subsequent investigation of the cutting mechanism. Subsequently, the removal mechanism of CF/PEEK during ultrasonic assisted milling is investigated through mesoscale finite element analysis (FEA) simulation, enabling detailed characterization of material removal behaviors at the composite interface. The results show that the damage below the machined surface was significantly reduced when the fiber direction angles were 45°, 90°and 135° during ultrasonic assisted milling. Surface microtopography under ultrasonic assisted milling conditions are compared through single-factor experiments, and the effects of process parameters on surface roughness and defect factor are systematically investigated. The results indicate that ultrasonic assisted milling reduces surface roughness by up to 46.5% and defect factor by up to 24.5% compared to conventional milling. By selecting appropriate parameters to conduct response surface experiments, analyze the interaction between spindle speed, feed rate per tooth, and amplitude on surface roughness and defect factors.</p>

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Research on the removal mechanism and surface quality of multi directional CF/PEEK plates by ultrasonic assisted milling

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • Zhongqing Wang,
  • Rongguo Hou,
  • Yusheng Li,
  • Hao Yun,
  • Xinyong Guo,
  • Zhe Lv

摘要

Carbon fiber reinforced polyetheretherketone (CF/PEEK) multidirectional plate material is used in new energy vehicles, aerospace and other fields due to its excellent mechanical properties and corrosion resistance. Due to the disparities in material properties between PEEK and carbon fiber, conventional milling operations often result in machining defects. This paper employs ultrasonic assisted milling (UAM) technology for the machining of CF/PEEK multidirectional composite laminates. First, a motion trajectory model for a specific point on a cutting edge during ultrasonic assisted milling is established, and the intermittent cutting behavior induced by axial vibration is analyzed, thereby establishing the theoretical foundation for subsequent investigation of the cutting mechanism. Subsequently, the removal mechanism of CF/PEEK during ultrasonic assisted milling is investigated through mesoscale finite element analysis (FEA) simulation, enabling detailed characterization of material removal behaviors at the composite interface. The results show that the damage below the machined surface was significantly reduced when the fiber direction angles were 45°, 90°and 135° during ultrasonic assisted milling. Surface microtopography under ultrasonic assisted milling conditions are compared through single-factor experiments, and the effects of process parameters on surface roughness and defect factor are systematically investigated. The results indicate that ultrasonic assisted milling reduces surface roughness by up to 46.5% and defect factor by up to 24.5% compared to conventional milling. By selecting appropriate parameters to conduct response surface experiments, analyze the interaction between spindle speed, feed rate per tooth, and amplitude on surface roughness and defect factors.