Effect of cutting parameters on surface roughness and tool wear in the end milling of NFRP composites
摘要
Machining natural fiber-reinforced polymer composites (NFRP) differs from machining synthetic fiber-reinforced polymers in several ways, including cutting forces, tool wear, and surface finish. This study investigates the impact of cutting parameters on surface roughness and tool wear during the machining of NFRP composites. The NFRP composites used in this work are Walnut Fiber Reinforced Polymer (WFRP), Date-palm Fiber Reinforced Polymer (DFRP), and Hybrid Fiber Reinforced Polymer (HFRP). The milling process was carried out on a CNC vertical machining center using High-Speed Steel (HSS) end mill tools. The effects of spindle speed and feed rate on surface roughness were analyzed using the Taguchi method and Analysis of Variance (ANOVA). The results indicate that spindle speed significantly affects surface roughness, with contributions of 93.41%, 94.67%, and 80.72% for WFRP, DFRP, and HFRP composites, respectively. The optimal spindle speed for minimum surface roughness was found to be 1592 rev/min with a feed rate of 150 mm/min for all composites. Additionally, a feed rate of 300 mm/min resulted in increased surface roughness. Scanning Electron Microscope (SEM) observations revealed that tool wear, including flank wear and Built-Up Edge (BUE) formation, was minimal at the optimum cutting parameters. The study also found that DFRP composites caused the least tool wear compared to WFRP and HFRP composites. These findings provide valuable insights for optimizing cutting parameters and improving tool life when milling NFRP composites.
Graphical Abstract