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The aerospace industry is advancing by using materials that combine lightweight properties with high performance. These materials, especially composites with metal fibers, pose distinct challenges in milling due to their individual material properties. If the milling parameters and tool choices are not meticulously planned, there is a risk of damaging the parts, which can lead to costly replacements. To optimize the milling of these hybrid materials, it's crucial to employ vibration monitoring to discern the effects of various parameters and tooling choices. This study assesses the efficiency of a tetrahedral amorphous carbon (ta-C) coated chip deflector tool when milling Fiber Metal Laminate (FML) composed by Carbon fiber reinforced plastic/Aluminium/Carbon fiber reinforced plastic (CFRP/Al/CFRP) and by Aluminium/Carbon fiber reinforced plastic/Aluminium (Al/CFRP/Al) laminates under uncooled conditions. Vibration monitoring served as a key indicator of tool wear. The tool wear and the shape of the chips produced during milling were examined using optical microscopy and Scanning Electron Microscopy (SEM) techniques. Findings indicated that higher cutting speeds correlated with intensified tool surface wear. Additionally, the morphology of the chips varied in response to changes in cutting speed.

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Vibration Monitoring and Tool Wear Analysis in Milling Fiber Metal Laminates for Aerospace Applications

  • 会议论文

  • 发表日期：

    2026年

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  • Rita C. M. Sales-Contini,
  • Naiara P. V. Sebbe,
  • Francisco J. G. da Silva,
  • Heide H. Bernardi,
  • Jorge T. Matsushima

摘要

The aerospace industry is advancing by using materials that combine lightweight properties with high performance. These materials, especially composites with metal fibers, pose distinct challenges in milling due to their individual material properties. If the milling parameters and tool choices are not meticulously planned, there is a risk of damaging the parts, which can lead to costly replacements. To optimize the milling of these hybrid materials, it's crucial to employ vibration monitoring to discern the effects of various parameters and tooling choices. This study assesses the efficiency of a tetrahedral amorphous carbon (ta-C) coated chip deflector tool when milling Fiber Metal Laminate (FML) composed by Carbon fiber reinforced plastic/Aluminium/Carbon fiber reinforced plastic (CFRP/Al/CFRP) and by Aluminium/Carbon fiber reinforced plastic/Aluminium (Al/CFRP/Al) laminates under uncooled conditions. Vibration monitoring served as a key indicator of tool wear. The tool wear and the shape of the chips produced during milling were examined using optical microscopy and Scanning Electron Microscopy (SEM) techniques. Findings indicated that higher cutting speeds correlated with intensified tool surface wear. Additionally, the morphology of the chips varied in response to changes in cutting speed.